KR20220164600A - Modular cascaded energy system with interchangeable energy source function with cooling unit - Google Patents

Abstract

Exemplary embodiments of systems, devices, and methods for cooling modular energy systems are provided herein. Embodiments may utilize an enclosure surrounding the modular energy system to route coolant in a manner that passes proximately to the components of the modules of the modular energy system. Embodiments may provide a sequence in which the coolant is pumped so that the coolant first cools the component of the electric vehicle with the lowest desired operating temperature, and then cools the component with a relatively higher desired operating temperature. Exemplary embodiments of systems, devices and methods are also provided herein for modular energy systems having removable and replaceable energy sources. The system can be deployed in an electric vehicle in such a way that energy sources with relatively low states of charge are quickly removed and these energy sources are replaced with different energy sources with relatively higher states of charge.

Description

Modular cascaded energy system with interchangeable energy source function with cooling unit

Cross reference to related applications

This application claims the benefit of, and claims priority to, U.S. Provisional Application No. 63/009,996, filed on April 14, 2020, and U.S. Provisional Application No. 63/086,003, filed on September 28, 2020, to these All are hereby incorporated by reference in their entirety, for all purposes.

The subject matter described herein generally relates to systems, devices, and methods for providing cooling to modular cascaded energy systems and providing the ability to detach and replace energy sources. .

Energy systems with multiple energy sources or sinks are common in many industries. One example is the automobile industry. Today's automotive technology, as it has evolved over the last century, is characterized by, among other things, the interplay of motors, mechanical elements, and electronics. These are key components that affect vehicle performance and driver experience. The motor is of the combustion type or electric type, and in almost all cases the rotational energy from the motor is transferred to highly sophisticated mechanical elements such as, for example, clutches, transmissions, differentials, drive shafts, torque tubes, couplers, etc. is passed through a set of These components greatly control the torque conversion and distribution of power to the wheels and define the performance of the car and its road handling.

BACKGROUND OF THE INVENTION An electric vehicle (EV) includes various electrical systems related to a drive system including, among other things, a battery pack, a charger, and a motor control. A high-voltage battery pack is typically composed of a series chain of lower-voltage battery modules. Each such module further includes a set of individual cells connected in series and a simple embedded battery management system (BMS) for regulating basic cell-related characteristics such as, for example, voltage and state of charge. include No electronic device exists with more sophisticated functionality or any form of smart interconnectedness. As a result, any monitoring or control function is handled by a separate system, which, although residing elsewhere in the vehicle, has no effect on individual cell health, state of charge, temperature, and performance. There is no ability to monitor other metrics that affect There is also no ability to meaningfully adjust the power draw per individual cell in any way. Some of the main consequences are: (1) the weakest cell limits the overall performance of the entire battery pack, (2) failure of any cell or module leads to the need to replace the entire pack, (3) battery reliability and safety are significantly reduced, (4) battery life is limited, (5) thermal management is difficult, (6) battery pack always operates below maximum performance, (7) regenerative braking is induced A sudden inrush of power may not readily be stored in the battery and requires dissipation through a dump resistor.

The charging circuit for an EV is typically realized in a separate on-board system. They stage power coming from outside the EV in the form of an AC or DC signal, convert it to DC and supply it to the battery pack. The charging system monitors voltage and current and normally supplies a stable and constant feed. Given the design of battery packs and typical charging circuitry, there is little functionality to tailor the flow of charge to individual battery modules based on cell health, performance characteristics, temperature, etc. Charge cycles are also typically long because charging systems and battery packs do not have the circuitry to allow for pulsed charging or other techniques to optimize charge transfer or total charge achievable.

Conventional controls include a DC to DC conversion stage to adjust the battery pack voltage level to the bus voltage of the EV's electrical system. The electric motor is, in turn, driven by a simple two-level polyphase converter that provides the required AC signal(s) to the electric motor. Each motor is controlled by a separate controller that drives the motor, traditionally in a three-phase design. A dual motor EV will require two controllers, while an EV using four in-wheel motors will require four separate controllers. Conventional controller designs also lack the ability to drive next-generation motors, such as switch reluctance motors (SRMs), which are characterized by a greater number of pole pieces. Adaptation will require a higher phase design, which will make the system more complex and ultimately will not address driving performance and electrical noise such as high torque ripple and acoustic noise, for example.

Many of these deficiencies apply not only to automobiles but also to other motor-driven vehicles, and to a great extent also to stationary devices. For these and other reasons, a need exists for improved systems, devices, and methods for mobile and stationary applications.

Exemplary embodiments of systems, devices and methods for cooling modular energy systems are provided herein. Embodiments may utilize an enclosure surrounding the modular energy system to route coolant in a manner that passes proximately to the components of the modules of the modular energy system. Embodiments may provide a sequence in which the coolant is pumped so that the coolant first cools the component of the electric vehicle with the lowest desired operating temperature, and then cools the component with a relatively higher desired operating temperature.

Exemplary embodiments of systems, devices and methods are also provided herein for modular energy systems having removable and replaceable energy sources. The system can be configured with a wide variety of different electrical configurations and electrically in such a way that energy sources with relatively lower states of charge can be quickly removed and these energy sources can be replaced with different energy sources with relatively higher states of charge. placed inside the car. The energy sources may be releasably latched in place within the electric vehicle such that each energy source is removable from electrical connection with its associated converter electronics.

Other systems, devices, methods, features, and advantages of the subject matter described herein will, or will become apparent, to those skilled in the art upon review of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, fall within the scope of the subject matter described herein, and be protected by the appended claims. Features of the illustrative embodiments should not be construed as limiting the scope of the appended claims in any way unless the features are explicitly recited in the claims.

Details of the subject matter described herein, both with respect to their structure and operation, may be apparent from a study of the accompanying drawings in which like reference numbers refer to like parts. Components in the drawings are not necessarily to scale; instead, emphasis is placed on illustrating the principles of the subject matter. Further, all examples are intended to convey a concept, and in all examples, relative sizes, shapes, and other attributes of detail may be illustrated diagrammatically rather than literally or precisely.
1A-1C are block diagrams illustrating an exemplary embodiment of a modular energy system.
1D to 1E are block diagrams illustrating an exemplary embodiment of a control device for an energy system.
1F-1G are block diagrams illustrating an exemplary embodiment of a modular energy system coupled with loads and charging sources.
2A-2B are block diagrams illustrating exemplary embodiments of modules and control systems within an energy system.
2C is a block diagram illustrating an exemplary embodiment of a physical configuration of a module.
2D is a block diagram illustrating an exemplary embodiment of a physical configuration of a modular energy system.
3A-3C are block diagrams illustrating exemplary embodiments of modules having various electrical configurations.
4A-4F are schematic diagrams illustrating exemplary embodiments of energy sources.
5A-5C are schematic diagrams illustrating exemplary embodiments of energy buffers.
6A-6C are schematic diagrams illustrating an exemplary embodiment of a converter.
7A-7E are block diagrams illustrating exemplary embodiments of modular energy systems having various topologies.
8A is a chart showing exemplary output voltages of the module.
8B is a diagram illustrating exemplary multi-level output voltages of a module array.
8C is a diagram illustrating exemplary reference and carrier signals usable in a pulse width modulation control technique.
8D is a diagram illustrating exemplary reference and carrier signals usable in a pulse width modulation control technique.
8E is a diagram illustrating an exemplary switch signal generated according to a pulse width modulation control technique.
8F is a chart showing exemplary multilevel output voltages generated by superposition of output voltages from an array of modules under a pulse width modulation control technique.
9A-9B are block diagrams illustrating an exemplary embodiment of a controller for a modular energy system.
10A is a block diagram illustrating an exemplary embodiment of a multiphase modular energy system with interconnection modules.
10B is a schematic diagram illustrating an exemplary embodiment of an interconnection module in the multiphase embodiment of FIG. 10A.
10C is a block diagram illustrating an exemplary embodiment of a modular energy system having two subsystems connected together by an interconnection module.
10D is a block diagram illustrating an exemplary embodiment of a three-phase modular energy system with interconnection modules supplying auxiliary loads.
10E is a schematic diagram illustrating an exemplary embodiment of an interconnection module in the multiphase embodiment of FIG. 10D.
10F is a block diagram illustrating an exemplary embodiment of a three-phase modular energy system with interconnection modules supplying auxiliary loads.
11A is a block diagram illustrating an exemplary embodiment of a process flow for cooling components of an electric vehicle.
11B is a perspective view illustrating an exemplary embodiment of an enclosure configured to cool a modular energy system.
11C is a block diagram illustrating another exemplary embodiment of a process flow for cooling components of an electric vehicle.
11D is a perspective view illustrating another exemplary embodiment of an enclosure configured to cool a modular energy system.
11E is a perspective view illustrating an exemplary embodiment of modular component placement relative to a top enclosure.
11F is a cross-sectional view illustrating an exemplary embodiment of a module proximate to a cooling device.
12A-12B are side views illustrating an exemplary embodiment of an electric vehicle configured to operate with a replaceable battery module.
13A is a schematic diagram illustrating an exemplary embodiment of a modular energy system with replaceable battery modules in an electric vehicle.
FIG. 13B is a block diagram illustrating an exemplary embodiment of an electrical layout for the modular energy system of FIG. 13A.
14a, 14d, 14e and 14f are perspective views illustrating exemplary embodiments of a converter module with interchangeable battery modules in various engaged and disengaged states.
14B-14C are cross-sectional views illustrating an exemplary embodiment of a housing for a modular electronic device.

Before the present subject matter is described in detail, it is to be understood that the present disclosure is not limited to the specific embodiments described and, as such, may of course vary. The terminology used herein is for the purpose of describing specific embodiments only and is not intended to be limiting, as the scope of the disclosure is to be limited only by the appended claims.

Before describing an exemplary embodiment of a cooling system and replaceable energy source, it is useful to first describe this basic modular energy system in more detail. Referring to FIGS. 1A-10F , the following sections include an embodiment of a modular energy system, i.e., an embodiment of a control system or device for a modular energy system, configuration of a modular energy system embodiment for charging sources and loads, Embodiments of individual modules, embodiments of topologies for arrangement of modules in a system, embodiments of control methodologies, embodiments of balancing operating characteristics of modules in a system, and embodiments of use of interconnection modules may be implemented. The various applications available are described.

example application

Stationary applications are applications in which the modular energy system is located in a fixed location during use, but can be moved to an alternate location when not in use. A module-based energy system is in a static location while providing electrical energy for consumption by one or more other entities, or storing or buffering energy for later consumption. Examples of stationary applications in which embodiments disclosed herein may be used include, but are not limited to: energy systems used or located on one or more residential structures or sites, on one or more industrial structures or sites. An energy system used or located on site, an energy system used or located on one or more commercial structures or sites, an energy system used or located on one or more governmental structures or sites (including both military and non-military uses), hereinafter energy systems (eg, charging sources or charging stations) for charging mobile applications described in , and systems for converting solar power, wind, geothermal energy, fossil fuels, or nuclear reactions into electricity for storage. Stationary applications often supply loads, for example grids and microgrids, motors and data centers. Stationary energy systems can be used in either storage or non-storage roles.

Mobility applications, sometimes referred to as traction applications, are generally module-based energy systems located on or in an entity, and motived by a motor to move or assist in moving that entity. It is an application that stores and provides electrical energy for conversion into force. Examples of mobile entities with which embodiments disclosed herein may be used are above or below land, above or below sea, apart from (e.g., flying or hovering in the air) over land or sea, or in outer space. electric and/or hybrid entities that move through (outer space), but are not limited thereto. Examples of mobile entities with which embodiments disclosed herein may be used include, but are not limited to, vehicles, trains, trams, ships, vessels, aircraft, and spacecraft. Examples of mobile vehicles with which embodiments disclosed herein may be used are those with only one wheel or track, those with only two wheels or tracks, those with only three wheels or tracks, those with only four wheels or those with tracks, and those with five or more wheels or tracks, but are not limited thereto. Examples of mobile entities with which embodiments disclosed herein may be used include cars, buses, trucks, motorcycles, scooters, industrial vehicles, mining vehicles, flying vehicles (eg, airplanes, helicopters, drones, etc.), marine vessels (eg, commercial transport vessels, ships, yachts, boats or other watercraft), submarines, locomotives or rail-based vehicles (eg, trains, trams, etc.), military vehicles, space vehicles, and satellites; However, it is not limited to these.

In describing embodiments herein, reference may be made to specific stationary applications (eg grid, microgrid, data centers, cloud computing environments) or mobile applications (eg electric vehicles). Such references are made for ease of description and do not imply that a particular embodiment is limited to use only in that particular mobile or stationary application. Embodiments of systems that provide power to motors may be used in both mobile and stationary applications. Although certain configurations may be better suited for some applications than others, all illustrative embodiments disclosed herein may be used in both mobile and stationary applications unless otherwise noted.

Examples of module-based energy systems

1A is a block diagram of an exemplary embodiment of a module-based energy system 100 . Here, the system 100 is a control system communicatively coupled with N transducer-source modules 108-1 through 108-N, respectively, via communication paths or links 106-1 through 106-N. 102). Module 108 is configured to store energy and output energy to load 101 (or other modules 108) as needed. In these embodiments, any number of two or more modules 108 may be used (eg, N is two or more). The modules 108 can be connected to each other in a variety of ways, which will be described in more detail with respect to FIGS. 7A-7E. For ease of illustration, in FIGS. 1A-1C , modules 108 are shown connected in series, or as a one-dimensional array, where the Nth module is coupled to load 101 .

System 100 is configured to supply power to a load 101 . Load 101 may be any type of load, such as a motor or grid, for example. System 100 is also configured to store power received from a charging source. 1F is a block diagram illustrating an exemplary embodiment of a system 100 having a power input interface 151 for receiving power from a charging source 150 and a power output interface for outputting power to a load 101. to be. In this embodiment, system 100 may receive and store power through interface 151 while simultaneously outputting power through interface 152 . 1G is a block diagram illustrating another exemplary embodiment of a system 100 having a switchable interface 154. In this embodiment, system 100 may select or be instructed to select between receiving power from charging source 150 and outputting power to load 101 . System 100 supplies multiple loads 101, including both primary loads and auxiliary loads, and/or multiple charging sources 150 (e.g., utility operated power grid and local renewables). may be configured to receive power from an energy source (eg, solar).

1B shows another exemplary embodiment of system 100 . Here, control system 102 communicates with N different local control devices (LCDs) 114-1 through 114-N, respectively, via communication paths or links 115-1 through 115-N. It is implemented as a possibly coupled master control device (MCD) 112 . each LCD 114-1 through 114-N is communicatively coupled to one module 108-1 through 108-N, respectively, via a communication path or link 116-1 through 116-N; As a result, there is a 1:1 relationship between LCD 114 and module 108.

1C shows another exemplary embodiment of system 100 . Here, MCD 112 is communicatively coupled with M different LCDs 114-1 through 114-M via communication paths or links 115-1 through 115-M, respectively. Each LCD 114 may be coupled with and control two or more modules 108 . In the example shown here, each LCD 114 is communicatively coupled with two modules 108, so that M LCDs 114-1 through 114-M are formed along a communication path or link 116-M. 1 to 116-2M) are combined with 2M modules (108-1 to 108-2M), respectively.

The control system 102 may be configured as a single device for the entire system 100 (eg, FIG. 1A), or may be distributed across or implemented as multiple devices (eg, FIGS. 1B-1C). can In some embodiments, control system 102 may be distributed among module 108 and associated LCDs 114 such that MCD 112 is not needed and can be omitted from system 100 .

Control system 102 may be configured to execute controls using software (instructions stored in memory executable by processing circuitry), hardware, or a combination thereof. One or more devices of control system 102 may each include processing circuitry 120 and memory 122 as shown herein. Example implementations of processing circuitry and memory are further described below.

The control system 102 may have a communication interface for communicating with a device 104 external to the system 100 via a communication link or path 105 . For example, control system 102 (e.g., MCD 112) may send data or information about system 100 to another control device 104 (e.g., a vehicle's electronic control unit in a mobile application). ; ECU) or Motor Control Unit (MCU), grid controller in stationary applications, etc.).

Communication paths or links 105, 106, 115, 116, and 118 (FIG. 2B) may be wired (e.g., electrical, optical) or wireless communication paths that bidirectionally communicate data or information in a parallel or serial manner, respectively. . Data may be conveyed in a standardized (eg, IEEE, ANSI) or user-specified (eg, proprietary) format. In automotive applications, the communication path 115 may be configured to communicate according to a FlexRay or CAN protocol. Communication paths 106 , 115 , 116 , and 118 may also provide wired power to directly supply operating power to system 102 from one or more modules 108 . For example, operating power for each LCD 114 may be supplied only by one or more modules 108 to which the LCD 114 is connected, and operating power for the MCD 112 (e.g., in an automobile) may be supplied indirectly from one or more of the modules 108 (via a power network).

The control system 102 is configured to control one or more modules 108 based on status information received from the same or different one or more modules 108 . Control may also be based on one or more other factors, such as, for example, the requirements of load 101 . Controllable aspects include, but are not limited to, one or more of voltage, current, phase and/or output power of each module 108 .

Status information of all modules 108 in system 100 can be passed to control system 102, which can independently control all modules 108-1...108-N. Other variations are also possible. For example, a particular module 108 (or subset of modules 108) can determine, based on status information of that particular module 108 (or subset), that particular module 108 (or subset). Based on the state information of all modules 108 other than that particular module 108 (or subset), based on state information of all modules 108 other than that particular module 108 (or subset), that particular module 108 (or subset) and the state information of at least one other module 108 other than that particular module (or subset), or based on the state information of all modules 108 in the system 100. .

State information may be information about one or more aspects, characteristics, or parameters of each module 108 . Types of status information include, but are not limited to, the following aspects of module 108 or one or more components thereof (eg, energy sources, energy buffers, transducers, monitor circuits): state of charge of one or more energy sources of the module ( State of Charge (SOC) (e.g., level of charge of an energy source relative to its capacity, e.g. fraction or percentage), State of Health (SOH) (e.g., energy compared to ideal conditions) of one or more energy sources of a module. figure of merit of the condition of the source), the temperature of one or more energy sources or other components of the module, the capacity of one or more energy sources of the module, the voltage of one or more energy sources of the module and/or other components, the one or more energy sources of the module, and /or the current of another component, and/or the presence or absence of a fault in one or more of the module's components.

LCD 114 receives status information from each module 108 or determines status information from monitored signals or data received from or within each module 108 and transfers that information to MCD 112. It can be configured to deliver to. In some embodiments, each LCD 114 may pass raw collected data to MCD 112, which then algorithmically determines status information based on the raw data. MCD 112 may then use the status information of module 108 to make a corresponding control decision. This determination may take the form of instructions, commands, or other information (e.g., modulation indices, described below) that may be utilized by LCD 114 to maintain or adjust the operation of each module 108. .

For example, MCD 112 may receive status information and evaluate the information to determine at least one module 108 (eg, its component) and at least one or more other modules 108 (eg, its comparable component). difference between them can be determined. For example, MCD 112 may determine that a particular module 108 is operating in one of the following conditions compared to one or more other modules 108: at a relatively lower or higher SOC, with a relatively lower or higher SOH, lower or higher capacitance, lower or higher voltage, lower or higher current, lower or higher temperature, or defective or without. In such instances, MCD 112 may (conditionally) output control information that causes a relevant aspect (eg, output voltage, current, power, temperature) of that particular module 108 to be reduced or increased. In this way, utilization of an outlier module 108 (e.g., operating at a relatively lower SOC or higher temperature) is such that the relevant parameter (e.g., SOC or temperature) of that module 108 is one or more of the other modules 108. ) can be reduced to converge to the relevant parameter of

A determination of whether to adjust the operation of a particular module 108 can be made by comparing state information to a predetermined threshold, limit, or condition, and not necessarily to the state of another module 108. does not The predetermined threshold, limit, or condition may be a static threshold, limit, or condition, such as those set by a manufacturer, that does not change during use. The pre-determined threshold, limit, or condition may be a dynamic threshold, limit, or condition that is permitted to change or is changed during use. For example, MCD 112 may cause module 108 to violate a predetermined threshold or limit (eg, above or below that predetermined threshold or limit), or to exceed a predetermined range of acceptable operating conditions. If the status information for that module 108 indicates that it is operating out of the way, then the operation of that module 108 can be adjusted. Similarly, MCD 112 indicates that if status information for a module indicates the presence of an actual or potential fault (e.g., an alert, or warning) or indicates the absence or elimination of an actual or potential fault, the corresponding The operation of module 108 can be adjusted. Examples of faults include, but are not limited to, actual failure of a component, potential failure of a component, short circuit or other excessive current condition, open circuit, excessive voltage condition, failure to receive communications, reception of corrupted data, and the like. does not Depending on the type and severity of the fault, the utilization of the faulty module can be reduced to prevent damage to the module or the utilization of the module can be stopped entirely.

MCD 112 may control modules 108 within system 100 to achieve or converge toward a desired goal. A goal may be, for example, the operation of all modules 108 at the same or similar level relative to each other, or within predetermined thresholds, limits, or conditions. This process is also referred to as balancing or seeking to achieve a balance in the operation or operating characteristics of the module 108 . As used herein, the term “balance” does not require absolute equivalence between modules 108 or components thereof, but rather, discrepancies in operation between modules 108 that would exist if the discrepancies were not actively reduced. It is used in a broad sense to convey that the operation of system 100 can be used to actively reduce.

MCD 112 may communicate control information to LCD 114 for the purpose of controlling module 108 associated with LCD 114 . The control information may be, for example, a modulation index and reference signal as described herein, a modulated reference signal, or the like. Each LCD 114 may use (eg, receive and process) control information to generate switch signals that control operation of one or more components (eg, transducers) within associated module(s) 108 . In some embodiments, MCD 112 directly generates the switch signal and outputs it to LCD 114, which relays the switch signal to the intended module component.

All or part of the control system 102 may be coupled with an external system control device 104 that controls one or more other aspects of a mobile or stationary application. When incorporated into this shared or common control device (or subsystem), control of the system 100 is controlled by one or more software applications executed by the shared device's processing circuitry in conjunction with the shared device's hardware, or a combination thereof. The same can be implemented in any desired way. Non-limiting examples of external control device 104 include a vehicle ECU or MCU having control functions for one or more other vehicle functions (eg, motor control, driver interface control, traction control, etc.); Grid or microgrid controller responsible for one or more other power management functions (e.g. load interfacing, load power requirement estimation, transmission and switching, interface with charging sources (e.g. diesel, solar, wind)), charging source power estimation, backup source monitoring, asset dispatch, etc.); and data center control subsystems (eg, environmental control, network control, backup control, etc.).

1D and 1E are block diagrams illustrating an exemplary embodiment of a shared or common control device (or system) 132 in which control system 102 may be implemented. In FIG. 1D , the common control device 132 includes a master control device 112 and an external control device 104 . Master control device 112 has interface 141 for communicating with LCD 114 over path 115 as well as interface 142 for communicating with external control device 104 over internal communication bus 136. include The external control device 104 has an interface 143 for communicating with the master control device 112 via the bus 136, and other entities of the overall application (eg vehicles or components of the grid) via the communication path 136. and an interface 144 for communicating with. In some embodiments, common control device 132 may be integrated as a common housing or package with devices 112 and 104 implemented as separate integrated circuit (IC) chips or packages contained therein.

In FIG. 1E , the external control device 104 acts as a common control device 132 and the master control functionality is implemented as a component 112 within the device 104 . This component 112 may be or include software or other program instructions stored and/or hardcoded in memory of device 104 and executed by processing circuitry of the device. A component may also include dedicated hardware. A component may be a stand-alone module or core with one or more internal hardware and/or software interfaces (eg, application program interfaces (APIs)) to communicate with the operating software of the external control device 104 . External control device 104 can manage communication with LCD 114 through interface 141 and other devices through interface 144 . In various embodiments, the device 104/132 may be integrated as a single IC chip, may be integrated into multiple IC chips in a single package, or may be integrated as multiple semiconductor packages within a common housing.

In the embodiment of FIGS. 1D and 1E , the master control functionality of system 102 is shared on a common device 132 , but other divisions of shared control are allowed. For example, some of the master control functionality may be distributed between common device 132 and dedicated MCD 112. In another example, at least a portion of the master control functionality and local control functionality may be implemented in common device 132 (eg, the remaining local control functionality is implemented in LCD 114). In some embodiments, all control systems 102 are implemented in a common device (or subsystem) 132. In some embodiments, the local control functionality is implemented within a device that is shared with another component of each module 108, such as, for example, a Battery Management System (BMS).

Examples of modules in a cascaded energy system

Module 108 may include one or more energy sources and power electronic converters, and energy buffers if desired. 2A-2B are block diagrams illustrating a further exemplary embodiment of a system 100 having a module 108 with a power converter 202, an energy buffer 204, and an energy source 206. The converter 202 may be a voltage converter or a current converter. An embodiment is described herein with reference to a voltage converter, but the embodiment is not limited thereto. Converter 202 may be configured to convert a direct current (DC) signal from energy source 206 to an alternating current (AC) signal and output it through power connection 110 (eg, an inverter). there is. Converter 202 may also receive an AC or DC signal through connection 110 and apply it to energy source 206 having either continuous or pulsed polarity. Converter 202 may be or include an array of switches (eg, power transistors), such as, for example, a half bridge (H-bridge) of a full bridge. In some embodiments, converter 202 includes only a switch and the converter (and the module as a whole) does not include a transformer.

Converter 202 may also (or alternatively) convert AC to DC (e.g., a rectifier), DC to DC conversion, and/or AC to AC, such as, for example, charging a DC energy source from an AC source. to (eg, for use with an AC-DC converter). For example, in some embodiments for performing AC to AC conversion, converter 202 may include a transformer alone or in combination with one or more power semiconductors (eg, switches, diodes, thyristors, etc.). In other embodiments, for example, where weight and cost are important factors, converter 202 may be configured to perform the conversion without a transformer and with only a power switch, power diode, or other semiconductor device.

The energy source 206 is preferably a rugged energy storage device capable of outputting direct current and having an energy density suitable for energy storage applications for electrically driven devices. A fuel cell can be a single fuel cell, multiple fuel cells connected in series or parallel, or a fuel cell module. Two or more energy sources may be included in each module, the two or more sources being two batteries of the same or different types, two capacitors of the same or different types, two fuel cells of the same or different types, one or more capacitors and /or one or more batteries coupled with fuel cells, and one or more capacitors coupled with one or more fuel cells.

Energy source 206 may be, for example, an electrochemical battery, such as a single battery cell, or multiple battery cells connected together in a battery module or array, or any combination thereof. 4A to 4D show a single battery cell 402 (FIG. 4A), a battery module having a series connection of multiple (e.g., four) cells 402 (FIG. 4B), and a parallel connection of single cells 402. An exemplary embodiment of an energy source 206 configured as a battery module ( FIG. 4C ) and a battery module having a parallel connection with legs ( FIG. 4D ) each having multiple (eg, two) cells 402 . It is a schematic diagram showing Examples of battery types are described elsewhere here.

The energy source 206 may also be a high energy density (HED) capacitor, such as an ultracapacitor or supercapacitor, for example. Unlike the solid dielectric type of common electrolytic capacitors, HED capacitors can be configured as double layer capacitors (static charge storage), pseudocapacitors (electrochemical charge storage), hybrid capacitors (electrostatic and electrochemical), etc. HED capacitors can have energy densities 10 to 100 times (or more) that of electrolytic capacitors, with higher capacitance. For example, the HED capacitor may have a specific energy greater than 1.0 Watt-hour per kilogram (Wh/kg) and a capacitance greater than 10 Farads (F) to 100 Farads (F). Like the battery described with respect to FIGS. 4A-4D , the energy source 206 may be configured as a single HED capacitor or multiple HED capacitors connected together in an array (eg, series, parallel, or combinations thereof).

Energy source 206 may also be a fuel cell. Examples of the fuel cell include a proton-exchange membrane fuel cell (PEMFC), a phosphoric acid fuel cell (PAFC), a solid acid fuel cell, an alkaline fuel cell, a high-temperature fuel cell, a solid oxide fuel cell, molten electrolyte fuel cells and the like. Like the battery described with respect to FIGS. 4A-4D , the energy source 206 may be configured as a single fuel cell or multiple fuel cells connected together in an array (eg, series, parallel, or combinations thereof). The foregoing examples of batteries, capacitors, and fuel cells are not intended to form an exhaustive list, and those skilled in the art will recognize other variations that fall within the scope of the present subject matter.

The energy buffer 204 can help maintain stability of the DC link voltage by attenuating or filtering the fluctuations in current across the DC line or link (eg, +V _DCL and -V _DCL described below). there is. These fluctuations may be relatively low (eg, kilohertz) or high (eg, megahertz) frequency fluctuations or harmonics caused by switching of converter 202 , or other transients. These fluctuations can be absorbed by buffer 204 instead of being passed to source 206 or to ports IO3 and IO4 of converter 202 .

Power connection 110 is a connection for transferring energy or power to module 108 , from module 108 , and through module 108 . Module 108 can output energy from energy source 206 to power connection 110 where it can be transferred to other modules in the system or to a load. The module 108 can also receive energy from other modules 108 or charging sources (DC charger, single phase charger, multi-phase charger). A signal may also pass through module 108 bypassing energy source 206 . The routing of energy or power into and out of module 108 is performed by converter 202 under the control of LCD 114 (or another entity in system 102).

In the embodiment of FIG. 2A , LCD 114 is implemented as a separate component from module 108 (e.g., not within a shared module housing) and is connected to and communicates with transducer 202 via communication path 116. can do. In the embodiment of FIG. 2B , LCD 114 is included as a component of module 108 and may be connected to and communicate with converter 202 via internal communication path 118 (eg, shared bus or separate connection). there is. LCD 114 may also receive and transmit signals from energy buffer 204 and/or energy source 206 via paths 116 or 118 .

Module 108 may also monitor (e.g., collect, sense, measure, and/or determine (or may be used, for example, by LCD 114 to determine status information). The primary function of the state information is to describe the state of one or more energy sources 206 of module 108 to allow a decision to be made about how much to utilize that energy source compared to other sources in system 100, but not the other components of the system 108. Status information describing the condition (eg, voltage, temperature and/or presence of a fault in buffer 204, presence of temperature and/or fault in converter 202, presence of fault elsewhere in module 108, etc.) can also be used The monitor circuitry 208 may include one or more sensors, shunts, dividers, fault detectors, coulomb counters, controllers, or other hardware and/or software configured to monitor these aspects. The monitor circuit 208 may be separate from the various components 202, 204, and 206, or may be separate from each of the components 202, 204, and 206 (shown in FIGS. 2A-2B) or any combination thereof. can be integrated In some embodiments, monitor circuitry 208 may be part of or shared with a battery management system (BMS) for battery energy source 206 . Separate circuits are not required to monitor each type of status information, as more than one type of status information can be monitored by a single circuit or device, or otherwise determined algorithmically without the need for additional circuitry.

LCD 114 may receive status information (or raw data) about module components via communication paths 116 and 118 . LCD 114 may also transmit information to module components via paths 116 and 118 . Paths 116 and 118 may include diagnostic, measurement, protection, and control signal lines. The transmitted information may be a control signal for one or more module components. The control signal may be a switch signal to converter 202 and/or one or more signals requesting status information from module components. For example, LCD 114 may be configured by directly requesting state information, or by applying a stimulus (e.g., voltage) such that state information is generated, in some cases in combination with a switch signal that places transducer 202 in a particular state. Status information may be transmitted over paths 116 and 118.

The physical configuration or layout of modules 108 can take many forms. In some embodiments, module 108 includes all module components, e.g., converter 202, buffer 204, and other optional components, e.g., LCD 114, into which source 206 is integrated. It may include a common housing accommodated together. In other embodiments, the various components may be separated in separate housings that are secured together. 2C shows a first housing 220, eg a transducer 202, which holds the module's energy source 206 and accompanying electronics, eg a monitor circuit 208 (not shown); LCD 114 for module 108 and second housing 222 holding module electronics, such as energy buffer 204, and other accompanying electronics such as, for example, monitor circuitry (not shown) is a block diagram showing an exemplary embodiment of a module 108 having a third housing 224 holding it (not shown). Electrical connections between the various module components can go through the housings 220, 222, 224 and any of the exterior of the housing for connection to other modules 108 or other devices such as MCD 112, for example. can be exposed from

Modules 108 of system 100 may be physically arranged relative to each other in a variety of configurations depending on the number of loads and needs of the application. For example, in a stationary application where system 100 provides power to a microgrid, module 108 may be placed in one or more racks or other frameworks. This configuration may also be suitable for larger mobile applications, such as for example on marine vessels. Alternatively, the modules 108 may be clamped together and placed within a common housing called a pack. A rack or pack can have its own dedicated cooling system shared across all modules. The pack configuration is useful for small mobile applications such as electric vehicles, for example. System 100 may be implemented with one or more racks (eg, for parallel supply to a microgrid) or one or more packs (eg, servicing different motors of a vehicle), or combinations thereof. FIG. 2D is a block diagram illustrating an exemplary embodiment of a system 100 configured as a pack having nine modules 108 electrically and physically coupled together within a common housing 230 .

Examples of these and additional configurations are in "Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations" filed on March 27, 2020, entitled "Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations". , and Methods Related Thereto", International Application No. PCT/US20/25366, which application is fully incorporated herein for all purposes.

3A-3C are block diagrams illustrating exemplary embodiments of modules 108 having various electrical configurations. These embodiments are described as having one LCD 114 per module 108, and the LCDs 114 are housed within associated modules, but may be configured differently as described herein. 3A shows a first exemplary configuration of module 108A in system 100 . Module 108A includes energy source 206, energy buffer 204, and converter 202A. Each component has a power connection port (eg, terminal, connector) through which power can be input and/or power can be output, referred to herein as an IO port. Such a port may also be referred to as an input port or an output port depending on the context.

Energy source 206 may be configured as any of the types of energy sources described herein (eg, a battery as described with respect to FIGS. 4A-4D , a HED capacitor, a fuel cell, or the like). Ports IO1 and IO2 of energy source 206 may be connected to ports IO1 and IO2 of energy buffer 204 , respectively. Energy buffer 204 may be configured to buffer or filter high-frequency energy pulsations and low-frequency energy pulsations that arrive at buffer 204 through transducer 202, which may otherwise degrade the performance of module 108. The topology and components for buffer 204 are chosen to accommodate the maximum allowable amplitude of these high frequency voltage pulsations. Several (non-limiting) exemplary embodiments of the energy buffer 204 are shown in the schematic diagrams of FIGS. 5A-5C. In FIG. 5A, buffer 204 is an electrolytic and/or film capacitor C _EB , and in FIG. 5B buffer 204 is two inductors L _EB1 and L _EB2 and two electrolytic and/or film capacitors C Z-source network 710 formed by _EB1 and C _EB2 , buffer 204 in FIG. 5C is two inductors L _EB1 and L _EB2 , two electrolytic and/or film capacitors C _EB1 and C _EB2 ) and a quasi Z-source network 720 formed by diode D _EB .

Ports IO3 and IO4 of energy buffer 204 may be connected to ports IO1 and IO2 respectively of converter 202A, which may be configured as any of the power converter types described herein. 6A is a schematic diagram illustrating an exemplary embodiment of converter 202A configured as a DC-AC converter that can receive DC voltage at ports IO1 and IO2 and switch to generate pulses at ports IO3 and IO4. . Converter 202A may include multiple switches, where converter 202A includes four switches S3, S4, S5, and S6 arranged in a full bridge configuration. Control system 102 or LCD 114 can independently control each switch for each gate via control input lines 118-3.

The switch may be, for example, a metal-oxide-semiconductor field-effect transistor (MOSFET), an insulated gate bipolar transistor (IGBT), or a gallium nitride (GaN) transistor as shown here. It may be any suitable switch type, such as a power semiconductor such as The semiconductor switch can be operated at a relatively high switching frequency, whereby, if desired, the converter 202 is operated in a pulse-width modulated (PWM) mode, and within relatively short time intervals. In can be allowed to respond to control commands. This can provide fast dynamic behavior and high tolerance of output voltage regulation in transient mode.

In this embodiment, a DC line voltage (V _DCL ) may be applied to converter 202 between ports IO1 and IO2 . By connecting V _DCL to ports IO3 and IO4 by different combinations of switches S3, S4, S5, and S6, converter 202 can generate three different voltage outputs at ports IO3 and IO4. : +V _DCL , 0 and -V _DCL . The switch signal provided to each switch controls whether the switch is on (closed) or off (open). While switches S3 and S6 are turned on while switches S4 and S5 are turned off to obtain +V _DCL , -V _DCL can be obtained by turning on switches S4 and S5 and turning off switches S3 and S6. The output voltage can be set to zero (including near zero) or a reference voltage by turning on S3 and S5 with S4 and S6 turned off, or by turning on S4 and S6 with S3 and S5 turned off. These voltages may be output from module 108 via power connection 110 . Ports IO3 and IO4 of converter 202 will be connected to module IO ports 1 and 2 of power connection 110 to generate an output voltage for use with the output voltage of another module 108 (or to can be formed).

The control or switch signals for the embodiments of converter 202 described herein may be generated in different ways depending on the control technique utilized by system 100 to generate the output voltage of converter 202 . In some embodiments, the control technique is a PWM technique, such as, for example, space vector pulse-width modulation (SVPWM) or sinusoidal pulse-width modulation (SPWM), or variations thereof. to be. 8A is a graph of voltage versus time showing an example of the output voltage waveform 802 of the converter 202. For convenience of explanation, the embodiments herein will be described in the context of PWM control technology, but the embodiments are not limited thereto. Other types of technology may be used. One alternative type is based on hysteresis, examples of which are described in International Patent Publication Nos. WO 2018/231810A1, WO 2018/232403A1 and WO 2019/183553A1, which are incorporated herein by reference for all purposes. included

Each module 108 may be comprised of multiple energy sources 206 (eg, two, three, four or more). Each energy source 206 in the module 108 can be controllable (switchable) to power the connection 110 (or receive power from a charging source) independently of the other sources 206 in the module. For example, all sources 206 may output power (or be charged) to connection 110 at the same time, or only one (or subset) of sources 206 may supply power at any given time. (or charged). In some embodiments, sources 206 of a module may exchange energy between themselves, eg, one source 206 may charge another source 206 . Each of the sources 206 may be configured as any of the energy sources described herein (eg, batteries, HED capacitors, fuel cells). Each of the sources 206 can be of the same type (eg, each can be a battery) or of a different type (eg, the first source can be a battery, the second source can be a HED capacitor, or the first source can be a battery). It may be a battery of a first type (eg NMC) and the second source may be a battery of a second type (eg LFP).

3B is a block diagram illustrating an exemplary embodiment of a module 108B in a dual energy source configuration having a primary energy source 206A and a secondary energy source 206B. Ports IO1 and IO2 of primary source 202A may be connected to ports IO1 and IO2 of energy buffer 204 . Module 108B includes converter 202B with additional IO ports. Ports IO3 and IO4 of buffer 204 may be connected to ports IO1 and IO2 of converter 202B, respectively. Ports IO1 and IO2 of secondary source 206B may be connected to ports IO5 and IO2 of converter 202B, respectively (also connected to port IO4 of buffer 204).

In this exemplary embodiment of module 108B, primary energy source 202A together with other modules 108 of system 100 supplies the average power required by the load. Secondary source 202B may function to provide additional power at load power peaks, absorb excess power, or otherwise assist energy source 202 .

As noted, both primary source 206A and secondary source 206B may be utilized simultaneously or at separate times depending on the switch state of converter 202B. If at the same time, an electrolytic and/or film capacitor (C _ES ) may be placed in parallel with source 206B as shown in FIG. 4E to act as an energy buffer for source 206B, or energy source 206B. ) may be configured to utilize a HED capacitor in parallel with another energy source (eg, battery or fuel cell) as shown in FIG. 4F.

6B and 6C are schematic diagrams illustrating exemplary embodiments of converters 202B and 202C, respectively. Converter 202B includes switch circuit parts 601 and 602A. Portion 601 includes switches S3 through S6 configured as a full bridge in a manner similar to converter 202A, selectively coupling IO1 and IO2 to one of IO3 and IO4 to change the output voltage of module 108B. is configured to Portion 602A is configured as a half bridge and includes switches S1 and S2 coupled between ports IO1 and IO2. Coupling inductor L _C is connected between node 1 and port IO5, which exists between switches S1 and S2, so that switch part 602A is a bi-directional converter capable of regulating voltage (or reverse current). Let it be. Switch portion 602A may generate two different voltages at node 1, +V _DCL2 and zero, referenced at port IO2, which may be at a virtual zero potential. The current drawn from or input to energy source 202B is passed through a coupled inductor L _C using, for example, a pulse width modulation technique or a hysteretic control method for rectifying switches S1 and S2. ) can be controlled by adjusting the voltage on the phase. Other techniques may also be used.

Converter 202C differs from 202B because switch portion 602B is configured as a half bridge and includes switches S1 and S2 coupled between ports IO5 and IO2. Coupling inductor L _C is connected between node 1 and port IO1 present between switch S1 and switch S2 such that switch portion 602B is configured to regulate the voltage.

Control system 102 or LCD 114 can independently control each switch of converters 202B and 202C via control input lines 118-3 for each gate. In these embodiments and the embodiment of FIG. 6A , LCD 114 (not MCD 112 ) generates the switching signal for the converter switch. Alternatively, MCD 112 may generate a switching signal that may be passed directly to a switch or relayed by LCD 114 .

In embodiments where the module 108 includes more than two energy sources 206, the converters 202B and 202C allow each additional energy source 206B to include additional switch circuits 602A or 602B depending on the needs of a particular source. ) can be scaled accordingly to be coupled to additional IO ports leading to For example, dual source converter 202 may include both switch portions 202A and 202B.

A module 108 having multiple energy sources 206 can, for example, share energy among the sources 206, capture energy from within an application (eg, regenerative braking), while the entire system is in a discharging state. It can also perform additional functions such as charging of the primary source by a secondary source, and active filtering of the module output. The active filtering function can also be performed by a module with a normal electrolytic capacitor instead of a secondary energy source. An example of such functionality is a patent filed on March 27, 2020 entitled "Module-Based Energy Systems Capable of Cascaded and Interconnected Configurations, and Methods Related Thereto )", International Application No. PCT/US20/25366, filed on March 22, 2019, entitled "Systems and Methods for Power Management and Control" It is described in Application Publication No. WO 2019/183553, both of which are incorporated herein by reference in their entirety for all purposes.

Each module 108 may be configured to supply one or more auxiliary loads with one or more energy sources 206 . The auxiliary load is a load that requires a lower voltage than the primary load 101 . Examples of auxiliary loads may be, for example, an on-board electrical network of an electric vehicle, an HVAC system of an electric vehicle. The load of system 100 may be, for example, either an electric vehicle motor or a phase of the electrical grid. This embodiment may allow complete decoupling between the electrical characteristics of the energy source (terminal voltage and current) and the electrical characteristics of the load.

3C is a block diagram illustrating an exemplary embodiment of a module 108C configured to supply power to a first auxiliary load 301 and a second auxiliary load 302, wherein module 108C is the same as that of FIG. 3B. energy source 206, energy buffer 204, and converter 202B coupled together in a similar manner. First auxiliary load 301 requires the same voltage as supplied from source 206 . Load 301 is coupled to IO ports 3 and 4 of module 108C, which in turn is coupled to ports IO1 and IO2 of source 206. Source 206 may output power to both power connection 110 and load 301 . Second auxiliary load 302 requires a lower constant voltage than source 206 . Load 302 is coupled to IO ports 5 and 6 of module 108C which are respectively coupled to ports IO5 and IO2 of converter 202B. Converter 202B may include a switch portion 602 having a coupled inductor L _C coupled to port IO5 ( FIG. 6B ). Energy supplied by source 206 may be supplied to load 302 through switch portion 602 of converter 202B. Load 302 has an input capacitor (alternatively, a capacitor can be added to module 108C), so switches S1 and S2 rectify to regulate voltage on and current through coupled inductor L _C . is assumed to be able to generate a stable constant voltage to the load 302. This regulation may step down the voltage of source 206 to a lower magnitude voltage required by load 302 .

Accordingly, module 108C may be configured to supply one or more first auxiliary loads in the manner described with respect to load 301, with one or more first loads coupled to IO ports 3 and 4. Module 108C may also be configured to supply one or more second auxiliary loads in the manner described with respect to load 302 . If multiple second auxiliary loads 302 are present, for each additional load 302 the module 108C has an additional dedicated module output port (eg, 5 and 6), an additional dedicated switch portion 602, and It can be scaled with additional converter IO ports coupled to additional portion 602.

Thus, energy source 206 can supply power to any number of auxiliary loads (eg, 301 and 302 ) as well as a corresponding portion of the system output power required by primary load 101 . The power flow from source 206 to the various loads can be adjusted as desired.

The module 108 is configured with two or more energy sources 206 (FIG. 3B) as needed and a switch portion 602 and converter port IO5 for each additional source 206B or second auxiliary load 302. may be configured to supply a first and/or second auxiliary load (FIG. 3c) through the addition of Additional module IO ports (eg 3, 4, 5, 6) can be added as needed. Modules 108 also interconnect to exchange energy (e.g., for balancing) between two or more arrays, two or more packs, or two or more systems 100, as further described herein. It can be configured as a module. This interconnection functionality may likewise be combined with multiple source and/or multiple auxiliary load supply functionality.

Control system 102 may perform various functions with respect to the components of modules 108A, 108B, and 108C. These functions may include management of utilization (usage) of each energy source 206, protection of the energy buffer 204 from overcurrent, overvoltage and high temperature conditions, and control and protection of the converter 202.

For example, to manage (e.g., adjust by increasing, decreasing, or maintaining) the utilization of each energy source 206, LCD 114 may monitor one or more monitored voltages from each energy source 206 (or monitor circuitry). , temperature and current can be received. The monitored voltage is at least one of the voltages of each basic component independent of the other components of the source 206 (e.g., each individual battery cell, HED capacitor and/or fuel cell), preferably all, or groups of basic components as a whole. may be the voltage of (eg, the voltage of the battery array, HED capacitor array, and/or fuel cell array). Similarly, the monitored temperature and current may be at least one, preferably all, or the temperature and current of a group of basic components as a whole, or any of the temperature and current of each basic component independent of the other components of the source 206. may be a combination of The monitored signal may be status information that allows LCD 114 to perform one or more of the following: calculation of actual capacity, actual state of charge (SOC) and/or state of health (SOH) of a basic component or group of basic components. or decision; setting or outputting a warning or alarm indication based on the monitored and/or calculated status information; and/or transmission of status information to MCD 112. LCD 114 will receive control information (e.g., modulation index, synchronization signal) from MCD 112 and use this control information to generate a switch signal for converter 202 that manages utilization of source 206. can

To protect the energy buffer 204, the LCD 114 may receive one or more monitored voltages, temperatures, and currents from the energy buffer 204 (or monitor circuitry). The monitored voltage is at least one, preferably all, of the voltages of each basic component (e.g. C _EB , C _EB1 , C _EB2 , L _EB1 , L _EB2 , D _EB ) of the buffer 204 independently of the other components, or the voltage of a group of basic components or buffers 204 as a whole (eg, between IO1 and IO2, or between IO3 and IO4). Similarly, the monitored temperature and current may include at least one, preferably all, of the temperature and current of each basic component of the buffer 204 independent of the other components, or the temperature and current of the group of basic components or buffer 204 as a whole. , or any combination thereof. The monitored signal may be status information that allows LCD 114 to do one or more of the following: set or output a warning or alert indication; pass status information to MCD 112; or controlling converter 202 to adjust (increase or decrease) utilization of source 206 and module 108 as a whole for buffer protection.

To control and protect converter 202, LCD 114 may receive control information from MCD 112 (e.g., a modulated reference signal, or a reference signal and modulation index), which is transmitted from LCD 114. It can be used with PWM technology to generate control signals for each switch (eg, S1 to S6). LCD 114 may receive a current feedback signal from the current sensor of converter 202, which may convey information about the faulty state (eg, short or open circuit failure mode) of all switches in converter 202. It can be used for overcurrent protection in conjunction with one or more fault condition signals from drive circuitry (not shown) of the converter switch. Based on this data, the LCD 114 manages the utilization of the module 108 and determines the switching signals to be applied to potentially bypass or disconnect the converter 202 (and the entire module 108) from the system 100. combinations can be determined.

When controlling module 108C that supplies second auxiliary load 302, LCD 114 monitors one or more monitored voltages on module 108C (e.g., the voltage between IO ports 5 and 6) and one or more monitored voltages. current (eg, the current of the coupled inductor L _C , which is the current of the load 302) may be received. Based on these signals, LCD 114 may adjust the switching cycles of S1 and S2 to control (and stabilize) the voltage across load 302 (eg, by adjusting the modulation index or reference waveform).

Example of Cascaded Energy System Topology

Two or more modules 108 may be coupled together in a cascaded array that outputs a voltage signal formed by the superposition of discrete voltages generated by each module 108 in the array. 7A shows an exemplary embodiment of a topology for a system 100 in which N modules 108-1, 108-2.., 108-N are coupled together in series to form a tandem array 700. It is a block diagram that In this and all examples described herein, N may be any integer greater than one. The array 700 includes a first system IO port (SIO1) and a second system IO port (SIO2) across which the array output voltage is generated. Array 700 may be used as a DC or single-phase AC energy source for DC or AC single-phase loads that may be connected to SIO1 and SIO2 of array 700 . 8A is a voltage versus time plot illustrating an exemplary output signal produced by a single module 108 having a 48 volt energy source. 8B is a voltage versus time plot illustrating an exemplary single-phase AC output signal produced by an array 700 having six 48V modules 108 coupled in series.

System 100 can be arranged in a wide variety of different topologies to meet the various needs of an application. System 100 may use multiple arrays 700 to provide multi-phase power (eg, 2-phase, 3-phase, 4-phase, 5-phase, 6-phase, etc.) to a load, where each array has a different phase angle. It is possible to generate an AC output signal with

7B is a block diagram illustrating system 100 having two arrays 700-PA and 700-PB coupled together. Each array 700 formed by serial connection of N modules 108 is one-dimensional. The two arrays 700-PA and 700-PB may each generate single-phase AC signals, where the two AC signals have different phase angles PA and PB (eg, 180 degrees out of phase). IO port 1 of module 108-1 of each array 700-PA and 700-PB may form or be connected to system IO ports SIO1 and SIO2, respectively, which in turn may be connected to a load (not shown) 2 It can be used as the first output of each array capable of providing phase power. Alternatively, ports SIO1 and SIO2 can be connected to provide single-phase power from two parallel arrays. IO port 2 of module 108-N of each array (700-PA and 700-PB) is connected to each array (700-PA and 700-PB) at the opposite end of the array from system IO ports (SIO1 and SIO2). It can be used as a second output, can be coupled together at a common node, and can optionally be used for an additional system IO port (SIO3) if desired, which can act as a neutral. This common node may be referred to as a rail, and IO port 2 of module 108-N of each array 700 may be referred to as being on the rail side of the array.

7C is a block diagram illustrating system 100 having three arrays 700-PA, 700-PB, and 700-PC coupled together. Each array 700 formed by serial connection of N modules 108 is one-dimensional. The three arrays 700-1 and 700-2 may each generate single-phase AC signals, where the three AC signals have different phase angles (PA, PB, PC) (eg, 120 degrees out of phase). IO port 1 of module 108-1 of each array (700-PA, 700-PB and 700-PC) may form or be connected to system IO ports (SIO1, SIO2 and SIO3), respectively, which in turn are 3 Phase power may be provided to a load (not shown). IO ports 2 of module 108-N of each array (700-PA, 700-PB and 700-PC) are coupled together in a common node and can optionally be used for an additional system IO port (SIO4) if desired , which can play a neutral role.

The concepts described with respect to the two-phase and three-phase embodiments of FIGS. 7B and 7C can be extended to system 100 generating even more phases of power. For example, a non-limiting list of additional examples include: system 100 having four arrays 700 each configured to generate single-phase AC signals with different phase angles (eg, 90 degrees out of phase); system 100 having five arrays 700, each configured to generate single phase AC signals with different phase angles (eg, 72 degrees phase difference); and a system 100 having six arrays 700, each configured to generate a single phase AC signal with a different phase angle (eg, 60 degrees out of phase).

System 100 may be configured such that array 700 is interconnected at electrical nodes between modules 108 in each array. 7D is a block diagram illustrating system 100 having three arrays (700-PA, 700-PB, and 700-PC) coupled together in a coupled series and delta arrangement. Each array 700 includes a first series connection of M modules 108 combined with a second series connection of N modules 108, where M is greater than or equal to two and N is greater than or equal to two. A delta configuration is formed by interconnections between arrays that can be placed in any desired location. In this embodiment, IO port 2 of module 108-(M+N) of array 700-PC is connected to IO port 2 of module 108-M of array 700-PA and module 108-( IO port 1 of module 108-(M+N) of array 700-PB is coupled with IO port 1 of module 108-M of array 700-PC. Port 2 and IO port 1 of module 108-(M+1) are coupled, and IO port 2 of module 108-(M+N) of array 700-PA is coupled to IO port 2 of array 700-PB. It is coupled with IO port 2 of module 108-M and IO port 1 of module 108-(M+1).

7E is a block diagram showing a system 100 having three arrays (700-PA, 700-PB, and 700-PC) coupled together in a coupled series and delta arrangement. This embodiment is similar to the embodiment of Figure 7d except with different cross connections. In this embodiment, IO port 2 of module 108-M of array 700-PC is coupled with IO port 1 of module 108-1 of array 700-PA, and array 700-PB IO port 2 of module 108-M in the array is coupled with IO port 1 of module 108-1 in the array 700-PC, and IO port 2 of module 108-M in the array 700-PA is coupled with IO port 1 of module 108-1 of array 700-PB. The arrangements of FIGS. 7D and 7E can be implemented with as few as two modules in each array 700 . Combined delta and series configurations allow for effective energy exchange between all modules 108 (interphase balancing) of the system and the phases of the power grid or load, and also the number of modules in the array 700 to obtain the desired output voltage. (108) to reduce the total number of

In the embodiment described herein, it is advantageous for the number of modules 108 to be the same in each array 700 in system 100, but such is not required and different arrays 700 will have different numbers of modules 108. can Further, each array 700 may be of the same configuration (e.g., all modules are 108A, all modules are 108B, all modules are 108C, etc.) or different configurations (e.g., one or more modules are 108A, one or more modules are 108A, etc.) may have modules 108 that are 108B, one or more are 108C, etc.). As such, the range of topologies of system 100 addressed herein is broad.

Exemplary Embodiments of Control Methodologies

As noted, control of system 100 may be performed according to various methodologies such as, for example, hysteresis or PWM. Some examples of PWM include space vector modulation and sinusoidal pulse width modulation, where the switching signal to converter 202 continuously rotates the utilization of each module 108 in phase to distribute power equally among them. It is created with the transitional carrier technology.

8C-8F are diagrams illustrating an exemplary embodiment of a phase-shifted PWM control methodology capable of generating multi-level output PWM waveforms using incrementally shifted bi-level waveforms. An X-level PWM waveform can be generated by summing (X-1)/2 bi-level PWM waveforms. This two-level waveform may be generated by comparing the reference waveform Vref with a carrier wave incrementally shifted by 360°/(X-1). The carrier wave is a triangle, but the embodiment is not limited to a triangle. A 9-level example is shown in FIG. 8C (using four modules 108). The carrier is incrementally shifted by 360°/(9-1) = 45° and compared to Vref. The resulting two-level PWM waveform is shown in FIG. 8E. This two-level waveform can be used as a switching signal for the semiconductor switches (eg, S1 to S6) of the converter 202. As an example with reference to FIG. 8E , for a one-dimensional array 700 comprising four modules 108 each having a transducer 202, the 0° signal is for control of S3 and the 180° signal is for the first module. 108-1 is for S6, 45° signal is for S3, 225° signal is for S6 of second module 108-2, 90° signal is for S3, 270° signal is for S6 of the third module 108-3, the 135° signal is for S3, and the 315° signal is for S6 of the fourth module 108-4. The signal to S3 is complementary to S4 and the signal to S5 is complementary to S6 with sufficient dead time to avoid shoot through of each half bridge. 8F shows an exemplary single-phase AC waveform generated by superposition (summing) of the output voltages from four modules 108.

An alternative is to utilize both positive and negative reference signals with the first (N-1)/2 carriers. A 9-level example is shown in FIG. 8D. In this example, the 0° to 135° switching signal (FIG. 8E) is generated by comparing +Vref to the 0° to 135° carrier in FIG. It is generated compared to the 135° carrier. In the latter case, however, the comparison logic is reversed. Other techniques, such as, for example, a state machine decoder, may also be used to generate the gate signals for the switches of converter 202.

In a multi-phase system embodiment, the same carrier may be used for each phase, or the set of carriers may be globally shifted for each phase. For example, in a three-phase system with a single reference voltage (Vref), each array 700 could use the same number of carriers with the same relative offset as shown in Figures 8c and 8d, but with a second phase The carrier of the first phase is shifted by 120 degrees compared to the carrier of the first phase, and the carrier of the third phase is shifted by 240 degrees compared to the carrier of the first phase. If a different reference voltage can be used for each phase, the phase information can be conveyed in the reference voltage and the same carrier can be used for each phase. In many cases the carrier frequency will be fixed, but in some exemplary embodiments the carrier frequency can be adjusted, which can help reduce losses in the EV motor in high current conditions.

Appropriate switching signals may be provided to each module by control system 102 . For example, MCD 112 can provide Vref and the appropriate carrier signal to each LCD 114 depending on which module or modules 108 the LCD 114 controls, then the LCD 114 may generate a switching signal. Alternatively, all carrier signals can be provided to all LCDs 114 in the array and the LCDs can select the appropriate carrier signal.

The relative utilization of each module 108 may be adjusted based on state information for performing balancing or one or more parameters described herein. Balancing of parameters may include utilization adjustments to minimize parameter divergence over time compared to systems in which individual module utilization adjustments are not performed. Utilization may be the relative amount of time the module 108 discharges when the system 100 is in a discharging state or the relative amount of time the module 108 charges when the system 100 is in a charging state.

As described herein, a module 108 may be balanced relative to another module of an array 700, which may be referred to as intra-array or intraphase balancing, and a different array 700 ) can be balanced against each other, which can be referred to as inter-array or inter-phase balancing. The array 700 of different subsystems can also be balanced against each other. The control system 102 can simultaneously perform any combination of intra-phase balancing, phase-to-phase balancing, utilization of multiple energy sources within a module, active filtering, and auxiliary load supply.

9A is a block diagram illustrating an exemplary embodiment of an array controller 900 of a control system 102 for a single phase AC or DC array. The array controller 900 may include a peak detector 902 , a divider 904 , and an in-phase (or in-array) balance controller 906 . Array controller 900 receives as input a reference voltage waveform (Vr) and status information for each of the N modules 108 in the array, and outputs normalized reference voltage waveform (Vrn) and modulation index (Mi) as output. can create Peak detector 902 detects the peak (Vpk) of Vr, which may be specific to the phase at which controller 900 operates and/or balances. Divider 904 generates Vrn by dividing Vr by the detected Vpk. The in-phase balance controller 906 uses Vpk along with state information (e.g., SOCi, Ti, Qi, Vi, etc.) to generate a modulation index Mi for each module 108 in the controlled array 700.

The modulation index and Vrn may be used to generate the switching signal for each converter 202. The modulation index can be a number between zero and one (including zero and one). For a particular module 108, the normalized reference (Vrn) may be modulated or scaled by Mi, and this modulated reference signal (Vrnm) may be according to the PWM technique described with respect to Figs. 8c to 8f or other techniques. It can be used as Vref (or -Vref) according to. In this way, the modulation index can be used to control the PWM switching signals provided to the converter switching circuits (e.g., S3-S6 or S1-S6) and thus adjust the operation of each module 108. For example, a module 108 controlled to maintain normal or full operation may receive Mi of 1, while a module 108 controlled to less than normal or full operation may receive Mi less than 1, and , the module 108 controlled to stop power output may receive Mi of zero. This operation is performed by, for example, MCD 112 outputting Vrn and Mi to an appropriate LCD 114 for modulation and switch signal generation, so that MCD 112 performs modulation for switch signal generation and modulates Vrnm. by the control system 102, either by outputting to an appropriate LCD 114, or by having the MCD 112 perform the modulation and switch signal generation and output the switch signal directly to the LCD or converter 202 of each module 108. It can be done in a variety of ways. Vrn may be continuously transmitted with Mi transmitted at regular intervals, for example once for every period of Vrn or once per minute, etc.

Controller 906 generates Mi for each module 108 using any type or combination of types of state information (e.g., SOC, temperature (T), Q, SOH, voltage, current) described herein. can do. For example, when using SOC and T, module 108 may have a relatively higher Mi if the SOC is relatively higher and the temperature is relatively lower than the other modules 108 in array 700. If the SOC is relatively low or the T is relatively high, that module 108 may have a relatively low Mi, and consequently is less utilized than other modules 108 in the array 700. Controller 906 can determine Mi such that the sum of the module voltages does not exceed Vpk. For example, Vpk may be the sum of the products of the voltage of the source 206 of each module and Mi for that module (eg, Vpk = M ₁ V ₁ +M ₂ V ₂ +M ₃ V ₃ ... + M _N V _N , etc.). Other combinations of modulation indices, and thus individual voltage contributions by modules, can be used but the total generated voltage must remain the same.

The controller 900 controls the SOC of the energy source(s) within each module 108 to balance or, if unbalanced, converge to a balanced condition, and/or the energy source(s) or other components within each module. (e.g., an energy buffer) to balance or, if unbalanced, to converge to a balanced condition, within a range that does not prevent the system from achieving its power output requirements at any point in time. . Power flow in and out of the module can be regulated so that differences in capacity between sources do not cause SOC deviations. Balancing SOC and temperature can indirectly cause some balancing of SOH. Voltages and currents can be directly balanced if desired, but in many embodiments the primary goal of the system is to balance SOC and temperature, and balancing SOC is the balancing of voltages and currents in highly symmetrical systems where the modules have similar capacities and impedances. can lead to

Balancing of any two or more parameters (SOC, T, Q, SOH, V, I), as it may not be possible to balance all parameters at the same time (e.g., balancing one parameter may further unbalance another parameter) A combination of can be applied with priority given to any one according to the requirements of the application. than the other parameters (T, Q, SOH, V, I) in balancing, except when one of the other parameters (T, Q, SOH, V, I) reaches a severely unbalanced condition outside the threshold. Priority may be given to SOC.

Balancing between arrays 700 of different phases (or arrays of the same phase if parallel arrays are used, for example) can be performed simultaneously with the intra-phase balancing. 9B shows an exemplary embodiment of an Ω-phase (or Ω-array) controller 950 configured for operation in an Ω-phase system 100 having at least Ω arrays 700, where Ω is Any integer greater than 1. Controller 950 includes one phase-to-phase (or inter-array) controller 910 and Ω in-phase balance controllers 906-PA .. 906-PΩ for phases PA through PΩ, as well as each phase-specific reference (VrPA). to VrPΩ) to generate a normalized reference (VrnPA to VrnPΩ) and a divider 904 (FIG. 9A). The in-phase controller 906 may generate Mi for each module 108 in each array 700 as described with respect to FIG. 9A . The phase balance controller 910 is configured or programmed to balance aspects of the module 108 throughout the entire multidimensional system, eg, between arrays of different phases. This may be accomplished through introducing a common mode into the phase (eg, neutral point shifting) or using an interconnection module (described herein) or both. Common mode introduction involves introducing phase and amplitude shifts to reference signals (VrPA to VrPΩ) to create normalized waveforms (VrnPA to VrnPΩ) to compensate for unbalance in one or more arrays, International Patent Application No. PCT/US20 /25366 for further explanation.

Controllers 900 and 950 (and balance controllers 906 and 910 ) may be implemented within control system 102 in hardware, software, or a combination thereof. Controllers 900 and 950 may be implemented within MCD 112, distributed partially or completely between LCDs 114, or implemented as separate controllers independent of MCD 112 and LCD 114. there is.

An Exemplary Embodiment of an Interconnection (IC) Module

A module 108 may be connected between modules of different arrays 700 to exchange energy between the arrays, to act as a source for an auxiliary load, or both. This module is referred to herein as an interconnection (IC) module 108IC. The IC module 108IC may be implemented in any of the previously described module configurations 108A, 108B, 108C and others described herein. IC module 108IC includes any number of one or more energy sources, optional energy buffers, switch circuitry for supplying energy to one or more arrays and/or supplying power to one or more auxiliary loads, control circuitry (e.g., local control device), and status information about the IC module itself or its various loads (e.g. SOC of the energy source, temperature of the energy source or energy buffer, capacity of the energy source, SOH of the energy source, voltage on the IC module and/or or monitor circuitry for collecting current measurements, voltage and/or current measurements on auxiliary load(s), etc.).

10A is a block diagram illustrating an exemplary embodiment of a system 100 capable of generating Ω-phase power in Ω arrays (700-PA through 700-PΩ), where Ω can be any integer greater than 1. can In this and other embodiments, the IC module 108IC is such that an array 700 (arrays 700-PA through 700-PΩ in this embodiment) to which the module 108IC is connected connects the module 108IC with the output (eg, SIO1 to SIOΩ) may be located on the rail side of the array 700 to be electrically connected. Here module 108IC has Ω IO ports to connect to IO port 2 of each module 108-N in array 700-PA through 700-PΩ. In the configuration shown here, module 108IC is implemented by selectively connecting one or more energy sources of module 108IC to one or more of arrays 700-PA through 700-PΩ (or, if phase-to-phase balancing is not required, Phase-to-phase balancing can be performed by not connecting to any output or by connecting to all outputs equally. System 100 may be controlled by control system 102 (not shown, see FIG. 1A).

10B is a schematic diagram illustrating an exemplary embodiment of module 108IC. The module 108IC in this embodiment includes an energy source 206 coupled to an energy buffer 204 coupled to a switch circuit 603 in turn. The switch circuit 603 may include switch circuit units 604-PA through 604-PΩ for independently connecting the energy source 206 to each of the arrays 700-PA through 700-PΩ. A variety of switch configurations can be used for each unit 604, in this embodiment configured as a half bridge with two semiconductor switches S7 and S8. Each half bridge is controlled by control line 118-3 from LCD 114. This configuration is similar to module 108A described with respect to FIG. 3A. As described with respect to converter 202, switch circuit 603 may be constructed in any arrangement and with any switch type (eg, MOSFET, IGBT, silicon, GaN, etc.) suitable for the requirements of the application.

The switch circuit unit 604 is coupled between the positive and negative terminals of the energy source 206 and has an output connected to the IO port of the module 108IC. Units 604-PA through 604-PΩ may be controlled by control system 102 to selectively couple voltages +V _IC or -V _IC to their respective module I/O ports 1 through Ω. Control system 102 may control switch circuit 603 according to any desired control technique including PWM and hysteresis techniques discussed herein. Here, the control circuit 102 is implemented as an LCD 114 and an MCD 112 (not shown). LCD 114 may receive monitoring data or status information from the monitor circuitry of module 108IC. This monitoring data and/or other status information derived from this monitoring data may be output to MCD 112 for use in system control as described herein. LCD 114 also provides timing information (not shown) for synchronization of module 108 of system 100 with one or more carrier signals (not shown), e.g., sawtooth signals used in PWM (Figs. 8C-8D). ) can be received.

For phase-to-phase balancing, proportionally more energy from source 206 may be supplied to any one or more of the arrays 700-PA through 700-PΩ at a relatively low state of charge compared to the other arrays 700. there is. Supply of this supplemental energy to a particular array 700 reduces the energy output of such cascaded modules 108-1 through 108-N in that array 700 relative to the unsupplied phased array(s). let it be

For example, in some demonstrative embodiments that employ PWM, LCD 114 provides a normalized voltage reference signal ( Vrn) (from MCD 112). LCD 114 may also receive, from MCD 112 , modulation indices (MiPA through MiPΩ) for switch units 604 -PA through 604 -PΩ for each array 700 , respectively. LCD 114 may modulate (eg, multiply) each individual Vrn with the modulation index for the switch section directly coupled to that array (eg, multiply VrnA by MiA), and then utilize the carrier signal. to generate control signal(s) for each switch unit 604. In another embodiment, MCD 112 may perform the modulation and output the modulated voltage reference waveform for each unit 604 directly to LCD 114 of module 108IC. In another embodiment, all processing and modulation may occur by a single control entity that may output control signals directly to each unit 604.

This switching can be modulated so that power from the energy source 206 is supplied to the array(s) 700 at appropriate intervals and durations. This methodology can be implemented in a variety of ways.

Based on the collected state information for system 100, such as, for example, the current capacity (Q) and SOC of each energy source in each array, MCD 112 calculates the total charge for each array 700. (e.g., the total charge for an array can be determined as the sum of the capacitance times the SOC for each module in the array). MCD 112 may determine whether a balanced or unbalanced condition exists (e.g., through use of relative difference thresholds and other metrics described herein), and each switch unit 604-PA through 604-PΩ) to generate modulation indices (MiPA to MiPΩ) accordingly.

During balanced operation, Mi for each switch unit 604 is such that the same or similar amount of net energy is supplied to each array 700 by the energy source 206 and/or energy buffer 204 over time. can be set to a value that For example, Mi for each switch unit 604 can be the same or similar, and the module 108IC drains the module 108IC at the same rate as the other modules 108 in the system 100. to a level or value that causes the module 108IC to perform a net discharge or time averaged discharge of energy to one or more arrays 700-PA through 700-PΩ during balanced operation. In some embodiments, Mi for each unit 604 may be set to a level or value that does not result in a net or time averaged discharge of energy during balanced operation (resulting in a net discharge of zero energy). This may be useful if module 108IC has a lower total charge than other modules in the system.

When an unbalanced condition occurs between the arrays 700, the modulation index of system 100 may be adjusted to cause convergence towards the balanced condition or to minimize further divergence. For example, control system 102 may cause module 108IC to discharge more into array 700 with a lower charge than others, and also allow modules 108-1 through 108 of that lower array 700 to -N) can cause relatively fewer discharges (eg, on a time average basis). The relative net energy contributed by module 108IC is increased compared to modules 108-1 through 108-N of supported array 700, and also the amount of net energy contributed by module 108IC compared to other arrays. . This increases Mi to the switch unit 604 supplying the corresponding low array 700, in a manner that maintains Vout for that low array at an appropriate or required level, and the module 108- of the low array 700 1 to 108-N), and keeping the modulation index for the other switch units 604 supplying (or reducing) the other upper arrays relatively unchanged.

The configuration of module 108IC of FIGS. 10A-10B can be used alone to provide phase-to-phase or inter-array balancing for a single system, or one or more switch portions 604 and energy sources coupled to one or more arrays, respectively. may be used in combination with one or more other modules 108IC having For example, a module 108IC having Ω number of switch portions 604 coupled with Ω different arrays 700 is a second module having Ω number of switch portions 604 coupled with one array 700 ( 108IC), so the two modules are coupled to service a system 100 having an Ω+1 array 700. Any number of modules 108IC may be coupled in this manner, each associated with one or more arrays 700 of system 100.

Moreover, the IC module may be configured to exchange energy between two or more subsystems of system 100. 10C is a block diagram illustrating an exemplary embodiment of a system 100 having a first subsystem 1000-1 and a second subsystem 1000-2 interconnected by IC modules. Specifically, subsystem 1000-1 is configured to supply three-phase power (PA, PB, and PC) to a first load (not shown) through system I/O ports (SIO1, SIO2, and SIO3), while , subsystem 1000-2 is configured to supply three-phase power (PD, PE, and PF) to a second load (not shown) through system I/O ports SIO4, SIO5, and SIO06, respectively. For example, subsystems 1000-1 and 1000-2 can be configured as different packs that power different motors of the EV or different racks that power different microgrids.

In this embodiment, each module 108IC connects to the first array of subsystems 1000-1 (via IO Port 1) and the first array of subsystems 1000-2 (via IO Port 2). coupled, and each module 108IC is electrically connected to one another via I/O ports 3 and 4 coupled to the energy source 206 of each module 108IC as described with respect to module 108C of FIG. 3C. can be connected. This connection places the sources 206 of modules 108IC-1, 108IC-2, and 108IC-3 in parallel, so the energy stored and supplied by modules 108IC are pulled together by this parallel arrangement. . Other arrangements may also be used, for example a serious connection. While module 108IC is housed within the common enclosure of subsystem 1000-1, the interconnection module may be outside the common enclosure and physically located as an independent entity between the common enclosure of both subsystems 1000. there is.

Each module 108IC has a switch unit 604-1 coupled with IO port 1 and a switch unit 604-2 coupled with I/O port 2, as described with respect to FIG. 10B. Thus, for balancing subsystems 1000 (e.g., inter-pack or inter-rack balancing), a particular module 108IC may supply relatively more energy to one or both of the two arrays to which it is connected ( For example, module 108IC-1 may supply array 700-PA and/or array 700-PD). The control circuitry can monitor the relative parameters (eg, SOC and temperature) of the arrays of different subsystems and adjust the energy output of the IC modules, as described herein, to determine imbalances between the two arrays in the same rack or pack. ) compensates for the imbalance between arrays or phases of different subsystems in the same way as compensating for . Because all three modules 108IC are in parallel, energy can be efficiently exchanged between any and all arrays in system 100. In this embodiment, each module 108IC supplies two arrays 700, but in a configuration with a single IC module for all arrays in system 100 and one dedicated IC module for each array 700 ( Other configurations may be used, including, for example, six IC modules for six arrays, where each IC module has one switch unit 604. In all cases with multiple IC modules, the energy sources can be coupled together in parallel to share energy as described herein.

Phase-to-phase balancing in systems with IC modules between phases can also be accomplished by neutral point shifting (or common mode introduction) as described above. This combination enables more robust and flexible balancing over a wider range of operating conditions. System 100 may determine appropriate circumstances to perform phase-to-phase balancing using neutral point shift alone, phase-to-phase energy injection alone, or a combination of both simultaneously.

The IC module may also be configured to power one or more auxiliary loads 301 (at the same voltage as source 206) and/or one or more auxiliary loads 302 (at a step-down voltage from source 302). can 10D is a block diagram illustrating an exemplary embodiment of a three-phase system 100A having two modules 108IC connected to perform phase-to-phase balancing and supply auxiliary loads 301 and 302. 10E is a schematic diagram illustrating this exemplary embodiment of system 100 with an emphasis on modules 108IC-1 and 108IC-2. Here, the control circuit 102 is implemented again as an LCD 114 and an MCD 112 (not shown). LCD 114 may receive monitoring data (eg, SOC of ES1, temperature of ES1, Q of ES1, voltage of auxiliary loads 301 and 302, etc.) from module 108IC, and may be configured as described herein. and/or output this and/or other monitoring data to MCD 112 for use in system control. Each module 108IC may include a switch portion 602A (or 602B as described with respect to FIG. 6C ) for each load 302 supplied by that module, each switch portion 602 comprising: It may be controlled by LCD 114 to maintain the required voltage level for load 302, either independently or based on control input from MCD 112. In this embodiment, each module 108IC includes a switch portion 602A connected together to supply one load 302, although this is not required.

10F is a block diagram illustrating another exemplary embodiment of a three-phase system configured to power one or more auxiliary loads 301 and 302 having modules 108IC-1, 108IC-2, and 108IC-3. to be. In this embodiment, modules 108IC-1 and 108IC-2 are configured in the same manner as described with respect to FIGS. 10D-10E. Module 108IC-3 is configured in a purely auxiliary role and does not actively inject voltage or current into any array 700 of system 100. In this embodiment, module 108IC-3 has converters 202B,C (FIGS. 6B-6C) with one or more auxiliary switch portions 602A, but the module of FIG. 3B (which omits switch portion 601) ( 108C). As such, the one or more energy sources 206 of module 108IC-3 are interconnected in parallel with the energy sources of modules 108IC-1 and 108IC-2, so this embodiment of system 100 is a secondary load. as additional energy to supply 301 and 302 and to maintain charge on source 206A of modules 108IC-1 and 108IC-2 through parallel connection with source 206 of module 108IC-3. It consists of

The energy source 206 of each IC module may, but need not be, be at the same voltage and capacity as the sources 206 of the other modules 108-1 through 108-N in the system. For example, in embodiments where one module 108IC energizes multiple arrays 700 (FIG. 10A) such that the IC modules discharge at the same rate as the modules of the phased array themselves, a relatively higher capacity is desirable. can do. If module 108IC also supplies an auxiliary load, a much larger capacity may be required so that the IC module can supply the auxiliary load and discharge at relatively the same rate as the other modules.

The foregoing embodiment described with respect to FIGS. 1A-10F will be used with all of the following embodiments relating to a cooling system for system 100 and implementation of system 100 within an application having removable and replaceable modules. can

Exemplary Embodiments of Cooling Systems

Since the amount of heat generated by system 100 during operation can be significant, the ability to circulate coolant in close proximity to the various elements and/or motors of system 100 and any other elements of the EV that require cooling. It is often necessary to provide a cooling system having 11A shows an example of a cooling arrangement 1100 in which coolant is pumped by a pump 1101 through various elements of the cooling arrangement 1100 . The coolant may circulate such that components with maximum cooling requirements are cooled first and components with more relaxed thermal requirements are cooled last. For example, in this embodiment, the pump 1101 first goes to the battery module 206, which may require coolant at a relatively low temperature between 20°C and 30°C, and then to a temperature of up to 40°C or 50°C. to power converter 202 and control electronics 1104 of module 108 (e.g., LCD 114) that may require coolant at relatively higher temperatures, and finally at higher temperatures below 60°C. Coolant may be circulated to one or more motors 1106 that may require coolant. After circulating coolant in close proximity to these components to cool them, the coolant may proceed through heat exchanger 1108 where the temperature of the coolant is lowered back to a temperature close to the requirements of battery module 206 and , at which point the coolant is circulated through the pump 1101 and the loop repeats.

One or more of the subsystems 1000 described herein may be implemented within a common enclosure. Energy storage systems contained within a common enclosure are often referred to as packs, for example battery packs. 11B shows an example of a common enclosure 1110 for one or more subsystems of system 100 . The common enclosure 1110 will contain each of the modules 108 of one or more subsystems and may also contain any interconnection modules present. The energy source, energy buffer, power electronics of the converter (switching circuit), control electronics and any other components of the module will be contained within a common enclosure 1110. For example, see FIG. 11E where the battery module 206 is located at the bottom and the associated power converter and control electronics 1104 are located above the battery in the enclosure. The common enclosure 1110 may include a bottom enclosure 1112, eg, a base, and an opposite top enclosure 1111, eg, a lid, both of which are Cooling of the module 108 may include one or more conduits for circulating coolant through this aspect of the enclosures 1111 and 1112 . As shown here, coolant from pump 301 can be circulated to bottom enclosure 1112 through a conduit network 1114 as shown for top enclosure 1111, thus in close proximity to the battery. passes through it to provide cooling to the battery. Coolant exits the bottom enclosure 1112 and passes through the top enclosure 1111 (either through conduits outside the enclosure 1110 or through conduits on the side or inside the enclosure 1110) and through the conduit network 1114. circulates through, wherein the coolant passes proximate to and cools the electronics of the module. The coolant may then exit the top enclosure 1111 where it may proceed to the next component of the system, such as the motor(s) 1106 for example.

In some embodiments, it is possible to provide coolant through only the top of enclosure 1111 and cool all aspects of module 108 without first cooling the battery and then subsequently cooling the electronics. 11C is an exemplary arrangement 320 where coolant is circulated from pump 301 to module 320 to simultaneously cool both the battery and associated electronics, and then to motor(s) 1106 and heat exchanger 1108. ) is shown. FIG. 11D shows an exemplary embodiment similar to FIG. 11B , but where coolant passes through the conduit network 1114 only within the top enclosure.

11E is a perspective view showing an exemplary layout for modules within enclosure 1110. Here, each module is shown as a battery adjacent to a converter (eg, the first module is a combination of Battery-1 and Converter-1, etc.). Only the top enclosure 1111 is shown here and the sides and bottom of the enclosure 1110 as well as the network of conduits within the top enclosure have been omitted for clarity. In this example, the converter is placed above the battery and the coolant is passed through the top enclosure 1111 above the converter, passing upwards through the converter to the top enclosure 1111 where heat from the battery is removed through the circulating coolant. A reverse configuration can also be implemented in which the converter is placed on the bottom and the battery is placed above the converter and heat is extracted back through the top enclosure in the case of FIG. 11e or through both the bottom and top in the case of FIG. 11b. In another embodiment, the converter and battery can be arranged as shown in FIG. 11E or in reverse configuration but coolant can only pass through the bottom enclosure. In another embodiment the converter and battery may be placed side by side and coolant may be circulated through the top enclosure and/or the bottom enclosure. All of the aforementioned variations can be implemented with the coolant also passing through a network of conduits at the top, bottom and/or side walls of the enclosure.

11F is a cross-sectional view of an exemplary embodiment in which the converter and control electronics 1108 are disposed above the battery 206. Although this embodiment will be described with respect to a conduit 1114 within the top enclosure 1111, the features of this embodiment may be applied to the conduit 1114 passing through the bottom of the enclosure or within the side of the enclosure as described. . In FIG. 11F , the electronics 1108 of the transducer and control system are contained within an electronics housing 1122 . The electronic device 1108 may be connected to one or more substrates, such as, for example, a printed circuit board (PCB) or an insulated metal substrate (IMS) substrate that provides electrical connections that pass between the various components. 1124) is mounted on it. The PCB or IMS is oriented over the electronics 1108 such that the electronics are mounted upside down. Battery 206 is located below housing 1122 and rests on base 1126, which may be a bottom enclosure. Battery 206 has a positive terminal and a negative terminal 1128 located on top of the battery. Electrical connections 1130 extend from terminal 1128 through housing 1122 (or alternatively outside of it) to the PCB or IMS and/or to the converter electronics for switching. The PCB or IMS is located immediately adjacent to a heatsink plate 1132 made of a high thermal conductivity material such as, for example, aluminum, aluminum alloy, copper, or steel.

The top enclosure 1111 includes a conduit 1114 for the coolant 1136 described with respect to FIGS. 11B and 11D. The conduit 1114 can be constructed from a material with high thermal conductivity, such as aluminum, copper, or steel, and can be formed with a polygonal cross-section as shown here, but for example, an elliptical shape or a circular shape or a circular shape. and other shapes may be used, such as combinations of polygonal shapes. A conduit 1114 may be located within a channel 1120 in the top enclosure 1111 having a shape corresponding to the conduit. For example, if conduit 1114 has a polygonal cross-section, channel 1120 may also have a polygonal cross-section allowing conduit 1114 to be placed therein. The top enclosure 1111 can also be constructed from a high thermal conductivity material, such as aluminum, copper or steel. Channel 1120 can be machined or etched into top enclosure 1111 and conduit 1114 can be press fit therein.

As shown here, two sections of conduit 1114 pass over certain modules 108 of system 100. If desired, interface layer 1134 may be between the bottom surface of conduit 1114 and the top surface of heatsink 1132 . Interface layer 1134 has a high degree of thermal conductivity and deformability or elasticity to form a continuous and durable contact between heatsink 1132 and the bottom surface of conduit 1114 (and also the bottom surface of top enclosure 1111). It may be a material with Interface layer 1134 may be relatively thinner than top enclosure 1111 and heatsink 1132 and interface layer 1134 may be composed of, for example, a thermally conductive polymer.

In this embodiment, the conduit 1114 is shown passing over one module, but the density of the conduit 1114 layout will vary based on the thermal requirements of the application. Preferably, at least one conduit 1114 passes over each module, but this is not required. A single conduit 1114 may be shared by two or more modules. Conduit 1114 can be routed up the center of the module or can be located approximately 1/3 of the distance from the side of the module as shown in FIG. 11F or otherwise positioned.

The configuration described with respect to FIG. 11F may achieve reliable cooling for the embodiments described herein using only the top enclosure of enclosure 1110 . As noted, a similar arrangement runs along the sides of enclosure 1110 and/or along the bottom of enclosure 1110 such that conduit 1114 is adjacent to or separated from the bottom of the battery by a second interface layer. can be placed accordingly.

Exemplary Embodiments of Removable Modules and Replaceable Modules

The example topology described herein may be configured to allow the energy source 206 of each module 108 to be removed and replaced from its location within the EV. This removable and replaceable feature allows a battery (or other energy source) with a relatively low charge to be quickly and conveniently replaced with a relatively higher charge, potentially significantly reducing the time required to charge an EV. . This capability is advantageous in environments where EVs are utilized for extended periods of time throughout the day, such as, for example, vehicle operations (eg ridesharing, delivery or car rental).

12A and 12B show an exemplary embodiment of an EV 1200 with replaceable battery (or other source) functionality. In this embodiment, each side of the EV (left and right) has one full battery access panel or door that is closed during operation of the EV and opened to allow access to spaces 1202 that hold the various batteries of system 100. total one). The battery may have a slim form factor such that the battery has a relatively long length and a relatively short height, as described in more detail herein. Because of its short height, the battery can be positioned along the bottom of the chassis so that any passenger or driver can rest on top of the battery and its modules without significantly increasing the overall height of the EV 1200. FIG. 12A shows EV 1200 with all one battery access door closed and FIG. 12B shows EV 1200 with battery access door 1201 open, in this case in the raised position. Opening all one of the battery access doors exposes a battery access space 1202 where each battery can be removed and replaced with another battery (or, in certain cases, the same battery after charging or repair).

In the embodiment of FIGS. 12A-12B and also of FIG. 13A described below, each battery is configured as a battery module (BM) having a number of cells. The modular energy system includes multiple subsystems for powering the different electric motors of EV 1200. Each battery module is referenced in terms of the subsystem it resides in, the phase of the array it resides in, and the level of the array it resides in that module houses the battery module. For example, the battery module associated with the first subsystem, the array for phase A of the first subsystem, and the module at level 2 of the array (e.g., module 108-2) is BM1A2 (Battery Module, Subsystem 1, referred to as Phase A, Level 2). The battery module associated with an interconnect module 108IC constructed in accordance with any embodiment described herein may, as an interconnect module (IC), have an accessible battery access door 1201 (L for left, R for right). ), and the number of interconnection modules (eg, 1, 2, 3). For example, the battery module that is part of the third interconnect module accessible from the left side of the vehicle is referred to as BMICL3. Transducer C in Fig. 13a is referenced in a similar manner.

13A is a cross-sectional plan view of an exemplary embodiment of EV 1200 having system 100 therein. In this embodiment, EV 1200 includes four in-wheel motors 1-4. Battery access doors 1201 are shown on the left and right. System 100 is configured in an electrical arrangement similar to that described with respect to FIG. 13B. In this embodiment, each motor is powered by three arrays each having three modules 108 therein. System 100 can be configured for any number (N) of modules in each array, where N is two or more. Here, each module is represented as a battery module combined with a converter, and other components are not shown. The transducer may include all electronics associated with the module (including the local control device 114 for that module). For example, battery-specific electronic devices such as a battery management system (BMS) may be co-located with the battery module. Power connections between modules are shown in the central area of EV 1200 . This connection can be implemented using insulated bus bars. The isolation bus bar may be arranged along an interior side of the converter, along the bottom of the converter, along the top of the converter, or any combination thereof as shown herein to efficiently transfer power. Although not shown, there is also data communication between the modules and with the master control device 112 .

Also shown are six IC modules 108IC. Interconnect modules (ICL1, ICL2, and ICL3) interconnect the subsystems that power motors 1 and 2, while interconnect modules (ICR1, ICR2, and ICR3) interconnect the subsystems that power motors 3 and 4. interconnect the Interconnection modules may be used to supply auxiliary loads (not shown) and perform phase-to-phase balancing.

14A is a perspective view illustrating an exemplary embodiment of a battery module 206 and a housing 1402 for module electronics. The battery module 206 can be configured with any standard operating voltage (eg, 24V, 48V, 60V, etc.) and has a slim form factor. The long dimension (length) shown here may be greater than 18 inches, while the width and height may be less than 6 inches. In other embodiments, the length may be at least twice the width, at least three times the width, at least four times the width, or at least five times the width. In this embodiment the width is approximately 1/2 the height. Housing 1402 is attached to guide rails 1404 that can guide the sliding motion of battery module 206 into electrical connection with transducers and other electronic devices (e.g., energy buffer 204, LCD 114). The battery module 206 has a positive terminal 1411 and an opposite negative terminal (not shown) as shown here. The direction may be reversed depending on the embodiment. Another configuration in which both the positive and negative terminals are on the same side (facing housing 1402) may be implemented as shown in FIG. 14F. Battery module 206 also has data connections (not shown) for conveying information about the battery, such as, for example, charge and temperature information, at which data connections an electrical connector labeled as BMS on housing 1402 and can be paired The battery module 206 may be latched or locked into a locked and connected position with the electronics within the housing 1402 . 14A shows one exemplary embodiment of a latch mechanism 1406 in the form of a panel that can rotate relative to a guard rail 1404 . The panel includes a power connector 1408(+) that can interface with the positive terminal 1411 of the battery. Another power connector 1409(-) is shown below the BMS port and may mate with the negative terminal of battery module 206.

14D shows the battery module 206 in the process of being slid into (or out of) electrical contact with the electronics within the housing 1402. FIG. 14E shows the battery module 206 after being fully advanced into contact with the electronics and raised to a locked position where the latch mechanism 1406 makes electrical contact with the positive terminal of the battery module 206 . Power from this connection can be routed along the bottom surface of the guard rail 1404 to the electronics at the opposite end. In the position of FIG. 14E , the battery module 206 is in a fixed position relative to the housing 1402 and all electrical connections between the battery 206 and the electronics within the housing 1402 have been made. The battery module 206 will be in the position shown in FIG. 14E during operation of the EV.

To remove a fully or partially discharged battery module 206, the EV's battery access door 1201 can be opened, the latch mechanism 1406 for that battery module 206 can be opened, and the battery Module 206 can be slid along guard rail 1404 out of electrical contact with the electronics and can be removed from EV 1200 through battery access door 1201 that is open. In this way, all battery modules 206 of all modules can be used in rapid succession to convert an EV 1200 with a low charge to an EV 1200 with a high charge or fully charged within approximately a few minutes (e.g., 5 minutes or less). can be removed and replaced.

14B is an end on view showing the opposite end of the housing 1402 with the BMS and power connector 1409(-) ports. Control and data ports for exchanging information with a local control device 114 (not shown) within the housing 1402 are shown here. Information from this control and data port can be routed to other modules in system 100 and to master control device 112 (not shown). Also shown are power connection ports 1 and 2 for connection to other components of system 100 depending on the location of the module within system 100 (eg, to another module or to a motor). See, for example, IO ports 1 and 2 of modules 108A-108C in FIGS. 3A-3C.

14C is a front view showing an end of the interconnect module housing 1402. The interconnect module 108IC is substantially the same as that described in FIGS. 14A, 14B, 14D, 14E and 14F, but to other interconnect modules 108IC and to auxiliary loads 301 and 302 (eg, FIG. 13B). It may be configured with additional power connection ports 3, 4, 5, and/or 6 for supplying power (eg, IO ports 3-6 of module 108C in FIG. 3C).

The various data and power connection ports described with respect to FIGS. 14A-14F may be implemented in any desired manner. For example, ports on battery module 206 may be configured as male ports designed to mate with corresponding female ports on housing 1402 and latch mechanism 1406, and vice versa. Same thing. The IO ports shown in FIGS. 14B and 14C are male or female ports designed to mate with bus bars or other connectors for carrying data and/or power to and/or from housing 1402. Each can be implemented as a port.

Although not limited thereto, the present embodiments may be used in conjunction with an electric vehicle having a universal EV platform, including an energy storage system and an electric powertrain having one or more motors attached thereto, an in-wheel motor without a drivetrain, or a combination thereof. can be used A universal EV platform is suitable for, for example, automated driverless and passengerless bodies (e.g., low voltage applications for automated delivery services), applications carrying at least one passenger or driver that do not require the transportation of heavy loads. for use with medium sized bodies (eg sedans or coupes or sports cars) (and thus with normal or medium voltage requirements), and with drivers and/or large loads (and thus with relatively higher voltage power requirements). ) the base frame of an EV that can be attached, coupled or otherwise integrated with any number of EV bodies depending on the specific application, such as a large size body for transporting multiple passengers (e.g. passenger bus, freight transport, etc.) or chassis.

Various aspects of the present subject matter are described below in light of, and/or as a supplement to, the embodiments described so far, with an emphasis on the interrelationships and interchangeability of the embodiments that follow. In other words, unless explicitly stated or otherwise taught, emphasis is placed on the fact that each feature of the embodiments may be combined with each and every other feature.

In many embodiments, a modular energy system controllable to power a load is provided, the system comprising a plurality of modules connected together to output an AC voltage signal comprising a superposition of a first output voltage from each module - each module comprising an energy source and transducer electronics connected to the energy source and configured to generate a first output voltage from the energy source; and an enclosure for the plurality of modules, the enclosure being configured to pass a coolant to cool the plurality of modules.

In some embodiments, the enclosure includes a conduit section configured to pass coolant. The enclosure may include a channel having a shape corresponding to the shape of the conduit section, wherein the conduit section is positioned within the channel. A conduit section may be press-fitted into the channel. A first module of the plurality of modules may have transducer electronics mounted on a substrate, and the substrate may be disposed between the conduit section and the transducer electronics of the first module. The substrate and transducer electronics may be disposed between the conduit section and the energy source of the first module. The system may further include a heat sink disposed between the conduit section and the substrate. The system may further include an interface layer disposed between the conduit section and the heat sink. The interface layer is deformable. The conduit section can contact the interface layer, the interface layer can contact the heat sink, and the heat sink can contact the substrate. Each of the plurality of modules may have transducer electronics mounted on a substrate, and the substrate may be disposed between the conduit section and the transducer electronics of each module.

In some embodiments, the enclosure includes a first base section, a second section opposite the base section, and a sidewall section. The conduit section can be in at least one of the first base section, the second section, and the sidewall section. The second section may be the lid of the enclosure and the conduit section is within the lid.

In a number of embodiments, a method of cooling a modular energy system of an electric vehicle is provided, the method comprising pumping a coolant through a cooling device proximate to the modular energy system so that the coolant cools the modules of the modular energy system. step of doing; thereafter, pumping a coolant proximate to the motor of the EV to cool the motor; and pumping the coolant through the heat exchanger to cool the coolant.

In some embodiments, pumping coolant through the cooling device includes pumping coolant proximate to at least one battery of a module of a modular energy system to cool the at least one battery; and then pumping a coolant proximate to the electronics of the module to cool the electronics.

In some embodiments, pumping the coolant through the cooling device includes pumping the coolant through a section of an enclosure of the modular energy system. The section may be at least one of a base section, a second section opposite the base section, and a sidewall section.

In some embodiments, pumping the coolant through the cooling device includes pumping the coolant through a base section of an enclosure of the modular energy system and then through a second section of the enclosure, opposite the base section. The batteries of the modules of the modular energy system may be located adjacent to the base section and the electronics of the modules of the modular energy system may be located adjacent to the second section. Pumping the coolant through the cooling device includes pumping the coolant through only one of the base section, the second section, and the sidewall section.

In many embodiments, a controllable modular energy system is provided to power a motor of an electric vehicle, the system including at least three arrays, each array having a superposition of a first output voltage from each module. a plurality of modules connected together to output an AC voltage signal comprising an energy source and converter electronics configured to generate a first output voltage from the energy source, outputted by an array of three An AC voltage signal that supplies three-phase power to the motor, and the energy source can be releasably connected to the converter electronics.

In some embodiments, the system further includes a latch mechanism configured to releasably connect the energy source to the transducer electronics. Each module may include a housing for holding the transducer electronics. The housing may be coupled to a guide rail for the energy source. The energy source may be slidable along the guide rail.

In some embodiments, the energy source has a width, a length and a height, where the length is at least twice the width. The length may be at least three times the width. The length may be at least four times the width.

In some embodiments, the latch mechanism includes a power connector for connecting the energy source to the transducer electronics.

In some embodiments, the system includes at least one interconnection module that includes an energy source and a transducer, the transducer of the interconnection module coupled to at least two of the arrays. The interconnection module can include a housing that holds the transducer of the interconnection module, the housing interconnecting a control port, at least two connectors for coupling the transducer to at least two of the arrays, and at least one auxiliary load. It includes at least two connectors for coupling the module's transducer or energy source.

In some embodiments, the energy source is a battery module. The housing of each module may include a connector for connecting the battery module's battery management system to a local control device housed within the housing.

In some embodiments, the system further includes a control system for controlling the transducer of the module. A control system may be configured to control intra-phase balancing within each array. A control system may be configured to control phase-to-phase balancing throughout the array.

In many embodiments, an electric vehicle is provided, the electric vehicle comprising: an electric motor; a modular energy system configured according to any of the embodiments described herein for powering an electric motor; and at least one access panel configured to move between a first position covering the energy source of the modular energy system and a second position exposing the energy source for removal.

In some embodiments, at least one access panel is a door configured to rotate.

In a number of embodiments, a method for managing power to an electric vehicle is provided, wherein the electric vehicle includes a modular energy system having at least three arrays, each array providing an AC voltage signal to a motor of the electric vehicle. a plurality of modules connected together in a cascaded fashion to create a battery module and converter electronics, the method comprising: removing a first battery module from a first location in an electric vehicle; ; and inserting the second battery module into the first location in the electric vehicle, wherein the second battery module has a relatively higher state of charge than the first battery module.

In some embodiments, removing the first battery module includes unlocking the first battery module from a locked state within the electric vehicle. The method may further include locking the second battery module in the first position.

In some embodiments, the method may further include moving an access panel of the electric vehicle from a closed position covering the first battery module to an open position exposing the first battery module prior to removing the first battery module. . The access panel may be under the passenger door.

In some embodiments, the method further includes removing all battery modules from the electric vehicle and inserting a different battery module having a relatively higher state of charge than the removed battery modules.

In some embodiments, removing the first battery module from the first location in the electric vehicle includes removing the first battery module from electrical contact with first converter electronics associated with the first battery module. Inserting the second battery module into the first location within the electric vehicle may include inserting the second battery module into electrical contact with the first converter electronics.

In some embodiments, removing the first battery module from the first location in the electric vehicle may include sliding the first battery module along a guide rail.

In some embodiments, inserting the second battery module into the first location within the electric vehicle may include sliding the second battery module along a guide rail.

The term "module" as used herein refers to one of two or more devices or subsystems within a larger system. A module may be configured to operate in conjunction with other modules of similar size, function, and physical arrangement (eg, location of electrical terminals, connectors, etc.). A module with the same function and energy source(s) may be configured (eg, size and physical arrangement) identically to all other modules in the same system (eg, rack or pack), but with different functions or energy source(s). The modules you have may differ in size and physical arrangement. Each module is physically removable and can, but is not required, be replaced in relation to other modules of the system (eg, a wheel of a car or a blade of an information technology (IT) blade server). For example, the system can be packaged in a common housing that does not allow removal and replacement of any single module without total disassembly of the system. However, any and all embodiments herein may be configured such that each module is removable and replaceable with respect to other modules in a conventional manner, eg, without disassembly of the system.

The term "master control device" is used herein in a broad sense and does not require implementation of any particular protocol, such as a master and slave relationship with any other device, eg, a local control device.

The term "output" is used herein in a broad sense and does not exclude functioning in a bidirectional manner as both an output and an input. Similarly, the term "input" is used herein in a broad sense and does not preclude functioning in a bidirectional manner as both an input and an output.

The terms "terminal" and "port" are used herein in a broad sense and may be either unidirectional or bidirectional, and may be input or output, e.g., female configuration or male It does not require any specific physical or mechanical structures such as construction.

A different reference number notation is used herein. This notation is used to facilitate explanation of the subject matter and does not limit the scope of the subject matter. Generally, a genus of an element is designated by a number, such as "123", and its subgenus is designated by adding a letter to the number, such as 123A or 123B. A reference to a genus without a letter appendix (e.g., 123) refers to the genus as a whole, including all subgenera. Some drawings show multiple instances of the same element. These elements may be appended with numbers or letters of the form "-X", for example 123-1, 123-2, or 123-PA. This -X format does not imply that elements must be configured identically in each instance, but is used to facilitate distinction when referring to elements in a drawing. A reference to genus 123 without -X adjuncts refers broadly to all instances of the element within the genus.

Various aspects of the present subject matter are described below in light of, and/or as a supplement to, the embodiments described so far, with an emphasis on the interrelationships and interchangeability of the embodiments that follow. In other words, emphasis is placed on the fact that each feature of an embodiment may be combined with each and every other feature, unless explicitly stated otherwise or logically incomprehensible.

A processing circuit may include one or more processors, microprocessors, controllers, and/or microcontrollers, each of which may be a separate or stand-alone chip or may be distributed among a number of different chips (and portions thereof). . of any type, such as but not limited to personal computing architectures (eg, those used in desktop PCs, laptops, tablets, etc.), programmable gate array architectures, proprietary architectures, custom architectures, and others. A processing circuit may be implemented. The processing circuitry may include a digital signal processor, which may be implemented in hardware and/or software. Processing circuitry may execute software instructions stored on memory that cause the processing circuitry to take many different actions and control other components.

The processing circuitry may also perform other software and/or hardware routines. For example, processing circuitry may interface with communications circuitry and perform analog-to-digital conversion, encoding and decoding, other digital signal processing, multimedia functions, data in a format suitable for presentation to communications circuitry (e.g., in-phase and quadrature). and/or may cause the communications circuitry to transmit data (wired or wireless).

Any and all communication signals described herein may be communicated wirelessly, except where noted or otherwise not logically pertinent. Communication circuitry may be included for wireless communication. Communication circuitry may be configured to enable wireless communication over a link under an appropriate protocol (eg, Wi-Fi, Bluetooth, Bluetooth low energy, Near Field Communication (NFC), Radio Frequency Identification (RFID), proprietary protocols, and the like). may be implemented as one or more chips and/or components (eg, transmitters, receivers, transceivers, and/or other communication circuitry) that perform One or more other antennas may be included along with the communication circuitry as needed to operate with various protocols and circuitry. In some embodiments, the communication circuitry may share an antenna for transmission over the link. RF communications circuitry may include a transmitter and a receiver (eg, integrated as a transceiver) and associated encoder logic.

The processing circuitry may also be adapted to run an operating system and any software applications, and to perform other functions not related to the processing of transmitted and received communications.

Computer program instructions for performing operations according to the described subject matter are object-oriented programming languages such as Java, JavaScript, Smalltalk, C++, C#, Transact-SQL, XML, PHP, or the like. and any combination of one or more programming languages, including conventional procedural programming languages such as the "C" programming language or similar programming languages.

Memory, storage, and/or computer readable media may be shared by one or more of the various functional units present, or distributed between two or more of them (e.g., as separate memory residing within different chips). It can be. The memory may also itself reside on a separate chip.

Where embodiments disclosed herein include or operate in connection with memory, storage, and/or computer readable media, then the memory, storage, and/or computer readable media are non-transitory. Thus, where memory, storage, and/or computer readable media are encompassed by one or more claims, then the memory, storage, and/or computer readable media are exclusively non-transitory. As used herein, the terms "non-transitory" and "tangible" are intended to describe memory, storage, and/or computer-readable media excluding propagating electromagnetic signals, but the persistence of storage or It is not intended to limit the type of memory, storage, and/or computer readable media in terms of externalities. For example, “non-transitory” and/or “tangible” memory, storage, and/or computer readable media may include, for example, random access media (eg, RAM, SRAM, DRAM, FRAM, etc.), read volatile and nonvolatile media such as proprietary media (eg, ROM, PROM, EPROM, EEPROM, flash, etc.) and combinations thereof (eg, hybrid RAM and ROM, NVRAM, etc.) and variants thereof.

It should be noted that all features, elements, components, functions, and steps described in connection with any embodiment provided herein are intended to be freely combinable and interchangeable with those of any other embodiment. If a particular feature, element, component, function, or step is described in connection with only one embodiment, then that feature, element, component, function, or step, unless expressly stated otherwise, is described herein. It should be understood that it can be used with any of the other embodiments described. Accordingly, this paragraph may, at any time, combine features, elements, components, functions, and steps of different embodiments, or may transfer features, elements, components, functions, and steps from one embodiment to another embodiment. claims that replace them serve as antecedent basis and written support for incorporating them, even if the description that follows does not explicitly state that, in particular cases, such combinations or substitutions are possible. It is expressly acknowledged that explicit recitation of all possible combinations and substitutions is unduly burdensome, especially considering that the permissibility of each and every such combination and substitution will be readily recognized by those skilled in the art.

As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. do.

While the present embodiments are susceptible to many modifications and alternative forms, specific examples thereof are shown in the drawings and described in detail herein. However, it should be understood that these embodiments are not limited to the specific forms disclosed, but rather to the contrary, that these embodiments will encompass all modifications, equivalents, and alternatives falling within the spirit of this disclosure. Moreover, any feature, function, step, or element of an embodiment is not limited to a claim, as well as a negative limitation that defines the inventive scope of a claim by a feature, function, step, or element not within its scope. described or may be added to them.

Claims (50)

A modular energy system controllable to supply power to a load, comprising:
A plurality of modules connected together to output an AC voltage signal comprising a superposition of a first output voltage from each module, each module connected to an energy source and the first output voltage from the energy source including transducer electronics configured to generate ; and
An enclosure for the plurality of modules
wherein the enclosure is configured to pass a coolant to cool the plurality of modules. According to claim 1,
The modular energy system of claim 1 , wherein the enclosure includes a conduit section configured to pass the coolant therethrough. According to claim 2,
wherein the enclosure includes a channel having a shape corresponding to a shape of the conduit section, and wherein the conduit section is positioned within the channel. According to claim 3,
wherein the conduit section is a press fit within the channel. According to claim 2,
wherein a first module of the plurality of modules has the converter electronics mounted on a substrate, the substrate disposed between the conduit section and the converter electronics of the first module. According to claim 5,
wherein the substrate and the converter electronics are disposed between the energy source of the first module and the conduit section. According to claim 5,
and a heat sink disposed between the conduit section and the substrate. According to claim 7,
and an interface layer disposed between the conduit section and the heat sink. According to claim 8,
wherein the interface layer is deformable. According to claim 8,
wherein the conduit section is in contact with the interface layer, the interface layer is in contact with the heat sink, and the heat sink is in contact with the substrate. According to claim 5,
wherein each of the plurality of modules has the converter electronics mounted on the substrate, the substrate disposed between the conduit section and the converter electronics of each module. According to any one of claims 2 to 9,
The modular energy system of claim 1 , wherein the enclosure includes a first base section, a second section opposite the base section, and a sidewall section. According to claim 12,
The modular energy system of claim 1 , wherein the conduit section is within at least one of the first base section, the second section, and the sidewall section. According to claim 13,
wherein the second section is a cover of the enclosure and the conduit section is within the cover. A method for cooling a modular energy system of an electric vehicle (EV), comprising:
pumping coolant through a cooling device proximate to the modular energy system so that the coolant cools the modules of the modular energy system;
thereafter, pumping the coolant proximate to the motor of the EV to cool the motor; and
and then pumping the coolant through a heat exchanger to cool the coolant.
Including, method. 16. The method of claim 15, wherein pumping the coolant through the cooling device comprises:
pumping a coolant proximate to at least one battery of a module of the modular energy system to cool the at least one battery;
thereafter, pumping a coolant proximate to the electronics of the module to cool the electronics.
Which includes, the method. According to claim 15,
wherein pumping coolant through the cooling device comprises pumping coolant through a section of an enclosure of the modular energy system. According to claim 17,
wherein the section is at least one of a base section, a second section opposite the base section, and a sidewall section. According to claim 15,
Wherein pumping coolant through the cooling device comprises pumping coolant through a base section of an enclosure of the modular energy system and then through a second section of the enclosure opposite the base section. . According to claim 19,
wherein the battery of the module of the modular energy system is located adjacent to the base section and the electronics of the module of the modular energy system are located adjacent to the second section. According to claim 17,
wherein pumping coolant through the cooling device comprises pumping coolant through only one of the base section, the second section, and the sidewall section. A controllable modular energy system to power a motor of an electric vehicle, comprising:
comprising at least three arrays, each array comprising a plurality of modules connected together to output an AC voltage signal comprising a superposition of first output voltages from each module, each module comprising an energy source and the energy converter electronics configured to generate the first output voltage from a source, wherein the AC voltage signals output by the three arrays supply three-phase power to the motor, and the energy source to the converter electronics A modular energy system that can be releasably connected. The method of claim 22,
and a latch mechanism configured to releasably connect the energy source to the converter electronics. According to claim 23,
wherein each module includes a housing for holding the converter electronics. According to claim 24,
The modular energy system of claim 1 , wherein the housing is coupled to a guide rail for the energy source. According to claim 25,
The modular energy system of claim 1 , wherein the energy source is slidable along the guide rail. The method of any one of claims 22 to 26,
wherein the energy source has a width, a length, and a height, wherein the length is at least twice the width. The method of claim 27,
The modular energy system of claim 1 , wherein the length is at least three times the width. The method of claim 27,
The modular energy system of claim 1 , wherein the length is at least four times the width. According to claim 23,
wherein the latch mechanism includes a power connector for connecting the energy source to the converter electronics. The method of any one of claims 22 to 30,
The modular energy system of claim 1 , wherein the system includes at least one interconnection module including an energy source and a converter, the converter of the interconnection module being coupled to at least two of the arrays. 32. The apparatus of claim 31 wherein said interconnection module includes a housing holding a transducer of said interconnection module, said housing comprising a control port, at least two connectors for coupling said transducer to said at least two of said array; and at least two connectors for coupling the energy source or the converter of the interconnection module to at least one auxiliary load. The method of any one of claims 24 to 32,
Wherein the energy source is a battery module. 34. The method of claim 33,
wherein the housing of each module includes a connector for connecting the battery management system of the battery module to a local control device housed within the housing. The method of any one of claims 22 to 34,
A modular energy system comprising a control system for controlling said converter of said module. The method of claim 35,
wherein the control system is configured to control intraphase balancing within each array. 37. The method of claim 36,
wherein the control system is configured to control interphase balancing across the array. In electric vehicles,
electric motor;
a modular energy system configured according to any one of claims 22 to 37 for powering the electric motor; and
at least one access panel configured to move between a first position covering an energy source of the modular energy system and a second position exposing the energy source for removal;
Including, an electric vehicle. 39. The method of claim 38,
The electric vehicle, wherein the at least one access panel is a door configured to rotate. A method of managing power for an electric vehicle comprising a modular energy system having at least three arrays, comprising:
each array includes a plurality of modules connected together in a cascaded fashion to generate an AC voltage signal for a motor of the electric vehicle, each module including a battery module and converter electronics; The method,
removing a first battery module from a first location in the electric vehicle; and
inserting a second battery module into the first position in the electric vehicle;
wherein the second battery module has a relatively higher state of charge than the first battery module. 41. The method of claim 40,
Wherein removing the first battery module comprises unlocking the first battery module from a locked state within the electric vehicle. The method of claim 41 ,
locking the second battery module in the first position. The method of any one of claims 40 to 42,
The method further comprising moving an access panel of the electric vehicle from a closed position covering the first battery module to an open position exposing the first battery module before the step of removing the first battery module. 44. The method of claim 43,
wherein the access panel is under a passenger door. The method of any one of claims 40 to 44,
The method further comprising removing all battery modules from the electric vehicle and inserting a different battery module having a relatively higher state of charge than the removed battery module. 46. The method of any one of claims 40 to 45,
wherein removing the first battery module from the first location in the electric vehicle includes removing the first battery module from electrical contact with first converter electronics associated with the first battery module. in, how. 47. The method of claim 46,
wherein inserting the second battery module at the first location in the electric vehicle comprises inserting the second battery module into electrical contact with the first converter electronics. The method of any one of claims 40 to 47,
Wherein removing the first battery module from the first location in the electric vehicle comprises sliding the first battery module along a guide rail. The method of any one of claims 40 to 47,
Wherein inserting the second battery module into the first position in the electric vehicle includes sliding the second battery module along a guide rail. The method of any one of claims 40 to 49,
The method of claim 22 , wherein the modular energy system is configured according to any one of claims 22 to 37.

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